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Custom EV battery trays and enclosures, heavy-gauge thermoformed for buses, delivery vans, and fleet packs. Ribs, gasket channels, and CNC-trimmed cooling ports.
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
Custom EV battery trays and enclosures locate and protect modules on electric buses, delivery vans, and heavy-duty fleet vehicles. We heavy-gauge thermoform flame-retardant sheet into a load-bearing tray, cover, or full pack housing, then 5-axis CNC trim the cooling ports, harness exits, and chassis mounts. Plastic construction adds electrical insulation and avoids the tooling cost of a large stamped-metal box or injection mold for low-to-medium volumes.
An on-road housing has to carry module weight, tolerate vibration and underbody impact, and keep road spray out of the pack. Heavy-gauge vacuum forming creates the structural shape in one piece: ribbed floors, module pockets, mounting lands, and gasket channels. Machined openings then match the battery management system, coolant lines, and fasteners in your CAD.
Sheet from 5 mm to 12 mm is selected for stiffness across the pack span. This page does not cover stationary energy-storage cabinets.
Electric Buses & Heavy-Duty Fleets
Electric Delivery Vans & Logistics Vehicles:
Energy Storage Systems (ESS) & Industrial Packs
Collaborative Co-Design & Engineering Partnership：
Facing design hurdles? Our engineering team partners closely with your team from the very start. We support 3D CAD modelling, draft angle optimisation and wall thickness analysis, ensuring your EV battery box meets strict industry requirements before mold fabrication commences.
100% Tailored Mold & Geometry Customization：
Move beyond the constraints of standard, ready-made parts. We manufacture custom molds that precisely match your battery module dimensions, complex contoured profiles, internal ribbing and proprietary mounting setups.
Smart Integration & Pre-Engineered Workflows：
We design structural housings around your in-built electrical systems. We can pre-engineer internal wiring pathways, cooling fluid routing cutouts and integrated mounting brackets to enable hassle-free installation of BMS and thermal pads.
Bespoke Material & Surface Selection：
Customise performance, durability and safety for your target application. Select from high-impact ABS/PC blends, flame-retardant thermoplastics, electrically insulating composites, or chemical-resistant coatings built to endure tough on-road operating conditions.
Low-Risk Prototyping to Mass Production：
Validate your concept via rapid prototyping and 5-axis CNC trimming prior to investing in full production tooling. Once the design is finalised, our high-volume thermoforming lines scale seamlessly to match your commercial EV production demands.
Our heavy-duty thermoformed plastic components are expertly engineered for a wide range of vehicle applications, including:
| ✔️ Electric bus and heavy-duty fleet battery enclosures | ✔️ Electric delivery van and logistics-vehicle pack housings |
| ✔️ Chassis-mounted and underbody EV battery trays | ✔️ Covers that register modules, cooling plates, and service fasteners |
| ✔️ Pilot and low-to-medium volume vehicle programs | |
Stationary racks and cabinet liners belong on our thermoformed battery enclosure page.
Q: What is a custom EV battery tray?
A: It is a heavy-gauge vacuum-formed base or housing that positions battery modules on a vehicle and provides mounts, ribs, and sealed interfaces for cooling and wiring.
Q: How thick are the trays?
A: Typically 5 mm to 12 mm. Final gauge depends on span, module mass, and impact targets.
Q: Can you meet an IP rating?
A: We design IP-oriented gasket channels and edge conditions to your specification. The assembled pack still needs your system-level sealing test.
Q: Which file formats do you quote from?
A: STEP, IGES, and STL, plus annual volume, cooling and BMS interface list, and any flame or sealing requirement.
Q: When is injection molding the better process?
A: When annual volume is high enough to pay for a large steel mold, or when the part needs many small molded-in clips. We will say so during design review.
Call to Action
Ready to bring your innovative aesthetic machine designs to life?
Send the pack CAD, vehicle type, and annual volume for a DFM review of your custom EV battery tray or enclosure.
Contact our engineering team at us to discuss your custom ergonomic aesthetic equipment housing project.
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.
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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.
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