Thick Gauge ABS/PC Battery Boxes in 8 mm – Solar And Wind Energy Range

These ABS/PC battery boxes are thick gauge vacuum formed parts supplied to drawing for solar and wind energy. They are formed from ABS/PC sheet at 8 mm, trimmed on 5-axis routers and inspected against the drawing before packing. Buyers choose this route where a metal fabrication is too heavy, or where injection moulding tooling cannot be justified for the volume.

Product specification

Key features

• One piece shell replaces a fabrication, so assembly hours drop
• ABS/PC keeps the weight down while stiffness is held through the formed shape
• Hot stamped accents finish as standard, further finishes on request
• Trimmed on 5-axis routers, so mounting holes and cut outs match the drawing
• Tooling stored against the part number for repeat and spare orders
• food contact declarations available

Typical applications

• cable covers
• nacelle access panels
• combiner box housings
• inverter covers
• battery boxes used across general solar and wind energy builds

How it is made

1. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
2. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
5. The part cools on a jig so the shape is held while the material stabilises.

Material: ABS/PC

ABS/PC carries higher heat resistance than ABS alone, which matters for housings around motors, drives and power electronics.

Design notes

• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• plan the trim line on a flat face so the router can hold tolerance

Finishing and assembly options

• hot stamped accents
• powder coat finish
• soft touch coating
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

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

• food contact declarations available
• dimension reports with every release
• ISO 9001 quality system

Packing and delivery

Parts are nested to save freight, with returnable dunnage available on repeat routes. Standard lead time to first article is 10–15 working days, and repeat releases ship against stored tooling without a new proving run.

Frequently asked questions

Are spare parts available later?

Tooling is stored against the part number for the life of the programme, so replacements or spare panels can be released at any time.

Can you make it in another material?

Any grade in this family can be swapped in. Send the requirement and the material will be quoted with the price difference shown.

What quantity can I order?

Sample quantities start at one piece off printed tooling. The process pays back from about 25 pieces a year and runs well into several thousand.

Request a quotation

Send the drawing or a photo of the current battery boxes with the quantity and the finish required. The reply covers material choice, wall thickness, tooling route and price, so the decision is made on a complete picture.