Thick Gauge ABS/PC Battery Boxes in 4 mm – Office Furniture Range

These ABS/PC battery boxes are thick gauge vacuum formed parts supplied to drawing for office furniture. They are formed from ABS/PC sheet at 4 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
• Powder coat finish 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
• material certificates with every batch

Typical applications

• screen frames
• desk modesty panels
• chair shells
• cable trays
• battery boxes used across general office furniture builds

How it is made

1. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
2. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
3. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
4. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
5. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.

Material: ABS/PC

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

Design notes

• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• 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
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Finishing and assembly options

• powder coat finish
• mould texture
• anti static coating
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

• material certificates with every batch
• RoHS compliant grades available
• REACH compliant sheet available

Packing and delivery

Each part is bagged, edges protected with foam, then cartonised for container loading. Standard lead time to first article is 7–15 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.

How fast is the first article?

Seven to fifteen working days from drawing release for sample tooling, with production tooling in three to four weeks.

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.