This page covers build-to-print aluminum and steel battery trays for mobile EV pack structures, sealing interfaces, module supports, covers and thermal-system integration. Drawings define the material, joining route, inspection datums and validation boundary for each OEM program. For stationary storage cabinets and non-vehicle housings, see our custom battery enclosures.
Released EV battery-tray designs vary by vehicle package, module layout, material, joining route and validation plan. Vehicle and mobile-equipment formats are reviewed here; stationary cabinets and racks follow a separate product and approval path.
Passenger EV Underbody battery enclosures for sedans, SUVs and crossovers. Released CTP architectures can include cooling interfaces and structural side members defined and validated by the vehicle OEM.
Commercial EV Heavy-duty battery enclosures for electric buses, trucks and last-mile delivery vehicles. Modular design with field-serviceable access panels and reinforced mounting points.
Separate Product Stationary BESS cabinets, racks and non-vehicle battery housings are not EV battery trays. Use the dedicated product page for cabinet structure, ventilation, service access and integrator-owned system approval requirements.
Specialty EV Compact battery boxes for e-bikes, scooters, forklifts, AGV/AMR robots and specialty mobile equipment. Quick-release designs with weather sealing and integrated charging port mounts.
Sheet metal, machining, joining, finishing and leak-check routes can be coordinated for a released battery-tray design. The quotation identifies process sources, acceptance criteria and record responsibility.
| Parameter | Planning boundary | Notes |
|---|---|---|
| Overall length | RFQ-defined | Released vehicle package and manufacturing route govern |
| Overall width | RFQ-defined | Released vehicle package and manufacturing route govern |
| Material thickness | Drawing-defined | Buyer-selected aluminum or steel specification |
| Wall thickness (extruded) | Drawing-defined | Buyer-selected profile specification |
| Dimensional tolerance | Drawing-defined | OEM defines CTQs and inspection criteria |
| General tolerance | Drawing-defined | RFQ identifies any referenced tolerance standard |
| Ingress protection | IP67 / IP69K targets when specified | OEM or laboratory validation per IEC 60529 |
| Leak test | RFQ-defined acceptance criterion | Buyer defines method, medium and test-party responsibility |
| Crash testing | OEM or accredited laboratory scope | DRAmetal does not claim vehicle-level crash validation |
| Flame resistance | Buyer-specified material requirement | Supplier declarations requested when included in the RFQ |
| Vibration | OEM or accredited laboratory scope | Input loads, fixture and acceptance remain buyer-defined |
| Production planning | Committed by project | After drawing, inspection and schedule review |
A representative production route from material review through drawing-defined inspection. Exact processes, sources and records are confirmed in the quotation.
DFM inputs can include topology, thermal and crash constraints when the OEM supplies the models and acceptance criteria. Prototype iterations depend on design maturity; no fixed reduction is claimed.
Material grade, temper, supplier documents, lot linkage and any independent composition or hardness checks are defined by the RFQ and inspection plan.
Fiber laser cutting for sheet components and CNC sawing for extruded profiles to the released drawing and agreed inspection criteria.
Machining of sealing lands, mounting interfaces and bosses can be included when the released drawing defines datums, tolerances and inspection method.
Welding or another joining route can be evaluated against the released aluminum joint. Process source, qualification, acceptance criteria and records are agreed before quotation and buyer approval.
Robotic MIG or TIG routes can be quoted for stable, repeat geometry. Path, fixture and acceptance requirements are defined by the released project plan.
Conversion coating, powder coat or anodize can be supplied to drawing-defined finish and corrosion-test requirements when included in the RFQ.
Leak and dimensional checks are performed only to the agreed method, acceptance limits and sampling plan. Records and traceability format are defined by RFQ.
The OEM selects material from structural, joining, corrosion, weight and validation requirements. We review the released grade, temper, thickness, supply condition and required material records for manufacturability.
Common lightweight project option
Smaller enclosures, two-wheeler boxes
Two-wheeler, ESS, specialty boxes
ESS, commercial heavy-duty
Marine ESS, harsh-environment specialty
Hybrid / multi-material designs
Battery enclosure interfaces affect sealing, fit and vehicle integration. The OEM defines safety requirements, validation and approval; DRAmetal follows the released mechanical drawing and agreed inspection plan.
DRAmetal is IATF 16949 and ISO 9001 certified. Certificate details are available on request. APQP, PPAP-style, FMEA and control-plan deliverables are supported only when defined and quoted for the program.
Drawing revision, first-article and inspection requirements are agreed before production. DRAmetal is ISO 9001 certified; certificate details are available on request.
Restricted-substance or environmental records are requested from applicable suppliers when specified.
The EV or battery-system OEM owns final UL and vehicle-level testing, approval and certification.
Calibrated dimensional method selected by RFQ
Method, medium, limit and test source defined by RFQ
OEM-owned system tests only when released and quoted
Responsible laboratory and acceptance criteria by RFQ
Supplier records or agreed independent checks by RFQ
ASTM B117 exposure only when the RFQ defines the responsible laboratory, duration, specimen and acceptance criteria
Materials, fabrication decisions and results for an anonymous customer project.
Component reference image
Impact deformation, water ingress, excessive mass and leaking welds affected the original pack structure.
Results apply to the project configuration described on the linked page.
Read the Customer Project →Sheet metal, extrusion, CNC, welding, finishing and leak-check routes can be coordinated under one quoted scope, including approved external processing where needed.
DFM review focuses on released interfaces, weld access, distortion, sealing lands, drainage and inspection feasibility for the quoted project.
Friction-stir welding can be evaluated for suitable aluminum enclosure joints when the drawing, material, joint design and acceptance requirements support it.
Prototype and repeat-production quantities are reviewed against tooling, inspection, purchased content and delivery requirements before commitment.
Technical questions, drawing markups and open issues are documented against the released package. Response timing depends on drawing and RFQ completeness.
Material, weld, leak-check and inspection records can be linked to the project when the format and retention period are agreed before production.
Send released CAD and drawings, material and thickness, joint specifications, sealing interfaces, CTQs, inspection and leak-test requirements, quantity or forecast, packaging, destination and required delivery date. We will define the quoted manufacturing scope and responsibility boundary.