800V EV Plastics Specialist
"Your EV Battery Housing Needs to Survive 1,200°C. Does Your Design Team Know How?"
800V EV architectures are moving from prototype to production. Hyundai, Kia, Porsche are already shipping. PEEK is entering automotive volume production for the first time. New regulations require battery housings to survive extreme flame tests. The materials playbook your engineers learned doesn't cover this.
Battery Housing Must Deliver
| Requirement | Challenge | ETS Solution |
|---|---|---|
| Thermal Management | -40°C to 85°C operation | Advanced material selection |
| Structural Integrity | Crash protection, vibration | FEA-validated designs |
| Fire Safety | Thermal runaway containment | Flame-retardant formulations |
| Lightweighting | Range extension goals | Topology-optimized structures |
| Sealing | IP67/IP68 ratings | Gasket and seal integration |
| Service Life | 15+ year warranty | Accelerated testing protocols |
Our EV Battery Services
Battery Housing Design
- Cell-level housings (cylindrical, prismatic, pouch)
- Module-level enclosures
- Pack-level bottom trays and top covers
- Venting strategies for pressure relief
Advanced Material Engineering
- 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 part geometry
- Quality control integration
Why ETS for EV Plastics?
The Knowledge Gap Is Real
Most plastics engineers were trained on commodity resins for conventional automotive. The 800V transition demands expertise in high-performance polymers, extreme thermal environments, and regulatory requirements that didn't exist five years ago.
- PEEK processing is unforgiving — Crystallinity control, mold temperatures above 180°C, and narrow process windows require deep material expertise
- Thermal runaway changes everything — Battery housing design must account for failure modes that no standard DFM checklist covers
- Weight targets are aggressive — Every gram matters for range, and plastics-to-metal conversion requires structural validation
- Compliance is evolving — UN 38.3, ECE R100, and OEM-specific requirements are a moving target
ETS brings 40+ years of plastics engineering discipline to this new frontier. We don't just know materials — we know how they behave in production, at scale, over time.
Use our Material Screener to compare EV-grade resins, or explore AI Design Validation for your next EV program.
Partner With ETS on Your EV Program
Whether you're designing your first battery housing or optimizing for high-volume production, we bring the plastics expertise your EV program needs.
Schedule EV Consultation