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Working on an advanced EV project and need OEM battery tray solutions? Or looking for engineering expertise to optimize your electric car battery box design for superior safety and lightweight efficiency?
You don’t need to handle the whole development process by yourself. Beyond standard manufacturing, we function as an extension of your R&D and engineering team.
We deliver joint co-design, structural optimization and fully custom EV battery enclosures. From rough hand sketches and reference CAD files to strict IP specifications, our experienced industrial designers and tooling engineers partner with you to turn concepts into market-ready heavy-gauge thermoformed and composite battery pack housings.
Forming Technology :
Heavy-Gauge Thermoforming / Vacuum Forming & 5-Axis CNC TrimmingCompatible Materials :
Flame-Retardant (FR) Thermoplastics, UL94 V-0 Rated Materials, High-Impact ABS/PC Blends, Electrically Insulating CompositesDesign Style :
Structural Load-Bearing Geometry, Integrated Rib Reinforcement, Custom Thermal/Cooling Routing IntegrationSurface Treatments :
Matte Industrial Texture, Anti-Corrosion Coating, IP-Sealed Gasket Channels, Custom Laser-Etched Product IdentificationSheet Thickness :
5mm – 12mm (Heavy-gauge sheets engineered for maximum structural rigidity, load-bearing capacity, and underbody impact resistance)Customization :
OEM/ODM tailored to 3D CAD files (STEP, IGES, STL) with DFM engineering, rapid prototyping, and custom tooling support
Upgrade your EV and energy storage systems with our electric bus battery trays and thermoformed parts. Our advanced heavy-gauge and vacuum thermoforming produces impact-resistant, flame-retardant plastic housings that easily integrate internal wiring paths, structural ribs and mounting hardware.
Tailored for EV fleets, commercial transport and industrial energy storage, our custom battery plastics balance safety, reliability and rugged outdoor performance with cost-effective tooling.
Why choose our custom thermoformed EV battery boxes and housings?
Energy Storage Systems (ESS) & Industrial Packs
Collaborative Co-Design & Engineering Partnership：
Facing design roadblocks? Our engineering team partners closely with your team from project initiation. We provide 3D CAD modelling, draft angle optimisation and wall thickness analysis to ensure your EV battery box meets strict industry standards prior to mold fabrication.
100% Tailored Mold & Geometry Customization：
Break free from constraints imposed by off-the-shelf components. We build custom molds precisely matched to your battery module dimensions, intricate 3D contours, internal ribs and proprietary mounting configurations.
Smart Integration & Pre-Engineered Workflows：
We design structural housings around your internal electrical systems. Our pre-engineered internal wiring conduits, cooling channels and integrated mounting brackets enable simple assembly for BMS and thermal pads.
Bespoke Material & Surface Selection：
Customise safety, durability and performance to match your application requirements. Material choices include high-impact ABS/PC blends, flame-retardant thermoplastics, insulating composites and chemical-resistant coatings formulated for harsh on-road operating environments.
Low-Risk Prototyping to Mass Production：
Validate your concept via rapid prototyping and 5-axis CNC trimming before committing to full tooling investment. Once your design is approved, our high-volume thermoforming lines scale seamlessly to support your commercial EV mass production demands.
Our heavy-duty thermoformed plastic components are expertly engineered for a wide range of electric vehicles and low-speed transports, including:
| ✔️ Passenger & Commercial Electric Vehicles (EVs) | ✔️ Electric Buses & Heavy-Duty Fleets |
| ✔️ Electric Delivery Vans & Logistics Vehicles | ✔️ Energy Storage Systems (ESS) & Industrial Packs: |
| ✔️ Electric Vehicle Battery Trays | |
Q: What materials are used for vacuum forming EV battery boxes and housings?
A: Our standard material selection includes heavy-duty UL94 V-0 flame-retardant thermoplastics, high-impact ABS/PC blends, and electrically insulating composites. These industrial-grade materials provide excellent chemical resistance and structural integrity, satisfying safety standards for tough automotive and energy operating environments.
Q: Is vacuum forming cheaper than metal stamping for custom battery enclosures?
A: Yes, especially for low to medium volume production. Heavy-gauge vacuum forming requires far lower initial mold and tooling investment than metal stamping dies. It is the ideal cost-saving option for large-format vehicle battery trays and protective cowlings.
Q: Can you customize the size, internal mounting brackets, and cooling channels of the battery housing?
A: Yes. Our full co-design service leverages precision 5-axis CNC machining. We can incorporate wiring cutouts, custom internal ribs, integrated cooling channels and custom mounting features to match your exact power system requirements.
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Thermoformed battery enclosures for energy storage and industrial packs. Heavy-gauge vacuum-formed trays, covers, and liners with thermal routing and service access.
Working on an advanced EV project and need OEM battery tray solutions? Or looking for engineering expertise to optimize your electric car battery box design for superior safety and lightweight efficiency? You don’t need to handle the whole development process by yourself. Beyond standard manufacturing, we function as an extension of your R&D and engineering team. We deliver joint co-design, structural optimization and fully custom EV battery enclosures. From rough hand sketches and reference CAD files to strict IP specifications, our experienced industrial designers and tooling engineers partner with you to turn concepts into market-ready heavy-gauge thermoformed and composite battery pack housings.
Looking for durable, weather-resistant protection for your electric and utility vehicles? Our custom golf cart plastic vacuum forming and heavy-gauge thermoforming parts are engineered using advanced heavy-gauge thermoforming technology. Designed to withstand harsh outdoor and rugged operating environments, these high-precision enclosures and canopies protect critical interior components while reducing total vehicle weight and enhancing the overall aesthetic appeal of your golf carts, UTVs, and LSVs.
Custom thermoplastic car components are vacuum-formed parts built to your CAD, with the openings, ribs, and mounting features the vehicle actually needs. We use heavy-gauge thermoforming and five-axis CNC trimming to produce exterior panels, hatches, underbody shields, interior trim modules, and conversion parts for passenger cars, commercial vehicles, and aftermarket programs. The process suits low-to-medium volumes where an injection mold is difficult to justify.
Heavy-gauge vacuum forming for automotive exterior body panels, dashboards, and underbody guards. Cost-effective tooling for specialty vehicles, utility fleets, and Tier-1 suppliers.
Large-format heavy-gauge thermoforming process capability. 5000×2500mm forming bed, 3–12mm sheet, 5-axis CNC trimming. Wide panels, equipment shells, EV enclosures. Free DFM review.
OEM heavy-gauge thermoformed EV charging station enclosures, pedestals, and outdoor protective canopies. Weather-resistant ASA/PC-ABS, UL 94 V-0 flame retardancy, precision CNC port cutouts.
OEM heavy-gauge thermoformed body panels for RVs, low-speed vehicles, UTVs, and golf carts. One-piece roofs, cowlings, side panels & cabin shells. UV-stable ABS/ASA. Free DFM review.
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