Battery Energy Storage Seat Shells in HIPS: Thick Gauge Forming and Specification

Vacuum formed seat shells are used across battery energy storage because they can be produced without the tooling spend of injection moulding and without the weight of sheet metal. This page covers how 3 mm HIPS sheet is formed for battery energy storage, what tolerances are realistic, and what has to be on the drawing before tooling starts.

The route below is the one used for most of the seat shells shipped from this plant: sheet is heated on the forming machine, drawn over an aluminium or composite mould, cooled on a jig, then trimmed on a 5-axis router. For seat shells the sheet gauge is selected from the load case rather than from habit, and HIPS is the material most often specified for this combination.

Typical specification

Where these parts are used

• vent shrouds for battery energy storage
• battery pack covers for battery energy storage
• cabinet liners for battery energy storage
• cell trays for battery energy storage
• seat shells in general battery energy storage builds

How the part is made

1. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
2. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. The part cools on a jig so the shape is held while the material stabilises.
6. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
7. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.

Material notes: HIPS

HIPS is the low cost route for indoor liners and disposable trays where impact strength is not critical.

Design tips for this part

• avoid sharp steps in the mould, which show as chill marks on the finished surface
• use corner radii of at least three times the sheet thickness to avoid thinning
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• plan the trim line on a flat face so the router can hold tolerance
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Quality and inspection

Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

Cost and lead time

Tooling is the main cost driver at low volume, so a 3 mm seat shells for battery energy storage is usually quoted with a composite or printed mould first and the aluminium tool cut once the design is frozen. That keeps the first article cost low and gives a real part to test before the production tool exists. The result is lower tooling cost compared with the alternatives, and a piece price that stays stable across repeat releases.

• Sample tooling: 7–15 working days
• Production tooling: 3–4 weeks
• Repeat orders run on stored tooling with no new proving run

Frequently asked questions

Can you match an existing part?

Yes. Send a sample or scan and the part can be reverse engineered, with the wall thickness and material measured from the sample.

What do you need to quote?

A 3D file or drawing, the material if it is fixed, the annual quantity and the finish. Photos of the current part are enough for a first estimate.

Do you supply certificates?

Material certificates, dimensional reports and flame retardancy or food contact declarations are issued with the shipment where the specification requires them.

Getting started

Send the drawing or a photo of the current seat shells with the quantity and the finish. The first reply is a manufacturability review with the wall thickness, material and a quotation, so the decision is made on facts rather than on a price alone.