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Case Studies

Custom Heavy-Gauge Thermoformed Trays for EV Battery & Components

Jul 15, 2026

 

Our custom heavy-gauge thermoformed trays are specifically engineered for the New Energy Vehicle (NEV) industry, widely utilized for electric vehicle (EV) battery trays, motor housings, and precision automotive component packaging. Designed to meet the rigorous demands of modern automated production lines and heavy-load logistics, these trays deliver superior performance, structural integrity, and maximum space efficiency.

 

 

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Key Features & Advantages

 

  • Custom Fit & Part Identification: Precisely molded to match the exact geometry of complex automotive parts, ensuring secure positioning, easy handling by robotic arms, and fast visual inspection.
  • Premium Engineering Plastics: Manufactured from high-quality materials (such as durable ABS), providing exceptional impact resistance, structural rigidity, and long-term durability.
  • Heavy-Load & Stackable Design: Engineered for safe multi-layer stacking and heavy-weight support, optimizing warehouse storage and transit safety.
  • Full Customization Services: We support comprehensive OEM/ODM customization—including custom textures, colors, and tailored dimensions—to meet your specific project requirements.

 

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Applications

 

  • EV Battery Packs & Trays
  • Electric Motor Housings & Precision Castings
  • Automotive Assembly Line WIP (Work-in-Process) Logistics

 

  • EV plate

    Empty Tray Stacking & Storage

    Empty trays are vertically stacked via edge-interlocking design, significantly reducing storage and transport space requirements.

  • EV plate

    Cylinder Head Loaded Transport

    Engine cylinder heads are neatly stacked on trays with precisely molded cavities, ensuring secure positioning and protecting precision machined surfaces during transport.

  • EV plate

    Custom-Cavity Tray

    Top view of a single empty tray featuring custom-molded cavities that match the exact geometry of the parts, providing precise positioning and impact protection.

  • EV plate

    Multi-Part Shared Tray Positioning

    Circular metal components are placed in corresponding recesses and reinforced ribs within the tray, enabling multi-part shared tray loading with precise cavity-based positioning..

  • EV plate

    Precision Assembly Protection

    A silver assembly component rests on a custom-molded tray with remaining cavities empty, designed for single-part high-precision protection or compatibility across multiple part variants.

 

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