OEM Battery Boxes polycarbonate in 8 mm for Material Handling

These polycarbonate battery boxes are thick gauge vacuum formed parts supplied to drawing for material handling. They are formed from polycarbonate 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
• polycarbonate keeps the weight down while stiffness is held through the formed shape
• Soft touch coating 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
• RoHS compliant grades available

Typical applications

• pallet tops
• conveyor covers
• tote liners
• picker truck panels
• battery boxes used across general material handling builds

How it is made

1. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
2. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. The part cools on a jig so the shape is held while the material stabilises.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Material: polycarbonate

Polycarbonate is used when the housing must survive impact or carry a glazing function. It must be dried before forming or the sheet will bubble.

Design notes

• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• use corner radii of at least three times the sheet thickness to avoid thinning
• plan the trim line on a flat face so the router can hold tolerance

Finishing and assembly options

• soft touch coating
• anti graffiti coating
• 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. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

• material certificates with every batch
• food contact declarations available
• PPAP or ISIR on request

Packing and delivery

Large panels are crated in made to measure wooden cases with corner protection. Standard lead time to first article is 3–4 weeks, and repeat releases ship against stored tooling without a new proving run.

Frequently asked questions

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.

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.

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.

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.