Thick Gauge HIPS Control Panels in 3 mm – Battery Energy Storage Range

These HIPS control panels are thick gauge vacuum formed parts supplied to drawing for battery energy storage. They are formed from HIPS sheet at 3 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
• HIPS keeps the weight down while stiffness is held through the formed shape
• As formed gloss 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

• battery pack covers
• cell trays
• cabinet liners
• vent shrouds
• control panels used across general battery energy storage builds

How it is made

1. The part cools on a jig so the shape is held while the material stabilises.
2. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
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. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.

Material: HIPS

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

Design notes

• use corner radii of at least three times the sheet thickness to avoid thinning
• 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
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Finishing and assembly options

• as formed gloss
• clear protective film
• EMI shielding 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.

• food contact declarations available
• ISO 9001 quality system
• UL94 V-0 grades 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

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.

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.

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 control panels 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.