HDPE Battery Boxes Vacuum Formed in 1.5 mm for Marine And Boat Building

These HDPE battery boxes are thick gauge vacuum formed parts supplied to drawing for marine and boat building. They are formed from HDPE sheet at 1.5 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
• HDPE keeps the weight down while stiffness is held through the formed shape
• Silk screened markings 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

• console shells
• battery box liners
• seat bases
• hatch covers
• battery boxes used across general marine and boat building builds

How it is made

1. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
2. The part cools on a jig so the shape is held while the material stabilises.
3. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Material: HDPE

HDPE is chosen for chemical resistance and impact strength at low temperature. It needs more heat and a longer cooling cycle than ABS, and it is painted only after flame or plasma treatment.

Design notes

• 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
• use corner radii of at least three times the sheet thickness to avoid thinning
• avoid sharp steps in the mould, which show as chill marks on the finished surface

Finishing and assembly options

• silk screened markings
• 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

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

• UL94 V-0 grades available
• RoHS compliant grades available
• food contact declarations available

Packing and delivery

Parts are stacked with interleaved film and packed in export cartons on pallets. 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

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.

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.

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.