Electrified-vehicle plastics · Hybrid, EREV, BEV
Electrification rewrote the spec sheet. Most teams were trained on the old one.
Higher voltages, thermal runaway, aggressive weight targets and a moving compliance target have pushed high-performance polymers into parts that used to be commodity resin. ETS brings 41 years of production discipline to the materials and failure modes your conventional DFM checklist never covered, on every powertrain your program still builds.
The battery enclosure brief
Six requirements. All at once.
A plastic battery housing or tray has to be a thermal, structural, fire, sealing and weight solution simultaneously, for a decade and a half. Optimizing any one in isolation breaks another.
| Requirement | The challenge | How ETS approaches it |
|---|---|---|
| Thermal management | -40°C to 85°C operation | Material selection from the thermal duty cycle backwards |
| Structural integrity | Crash protection and vibration | FEA-validated designs checked against production outcomes |
| Fire safety | Thermal-runaway containment | Flame-retardant formulations and venting strategy |
| Lightweighting | Range and payload targets | Topology-optimized structure; plastics-to-metal conversion validated |
| Sealing | IP67 / IP68 ratings | Gasket and seal integration designed with the housing |
| Service life | 15+ year warranty | Creep, fatigue and aging addressed with accelerated testing protocols |
What we do
From cell housing to high-volume tool.
Engagements run as fixed-scope projects, retainers or design reviews.
Battery housing design
- Cylindrical, prismatic and pouch cell housings
- Module-level enclosures
- Pack bottom trays and top covers
- Venting for pressure relief
Advanced materials
- PEEK and PEI for extreme environments
- Long-fiber reinforced thermoplastics
- Flame-retardant formulations
- UV-stable exterior materials
Design for EV manufacturing
- High-volume production optimization
- Multi-cavity mold design
- Automation-ready geometry
- Quality control integration
The knowledge gap
Four ways electrified programs catch good teams out.
We don’t just know the materials. We know how they behave in production, at scale, over time.
High-performance resins are unforgiving
Crystallinity control, mold temperatures above 180°C and narrow process windows. Trial and error at high-performance resin prices is a budget line nobody approved.
Thermal runaway changes the failure analysis
Housing design must account for failure modes no standard DFM checklist covers.
Every gram is range
Plastics-to-metal conversion needs structural validation, not optimism.
Compliance keeps moving
UN 38.3, ECE R100 and OEM-specific requirements evolve through the program. Designs have to be ready for the version that ships.
Next step
Bring us the part that has to survive everything.
Designing your first battery housing or optimizing for volume: tell us the program stage and we’ll scope it within one business day.
- NDA on request
- Senior engineer replies in one business day
- Fixed price where applicable
- Your data stays yours