---
title: "Thermoformed EV Battery Trays & Energy Housings | FUNYO"
description: "Thermoformed parts for EV batteries and energy equipment. FUNYO provides 1–3 week tooling, sheet forming and CNC trimming to drawings."
type: landing
---

# Thermoformed EV Trays & Housings

We started with large battery trays. Now we make charger housings too.

Thermoformed EV Trays & Housings are shaped from heated plastic sheet. FUNYO forms single parts up to 2600 × 1600 × 600 mm from sheet up to 15 mm; housings commonly use 8–10 mm. Forming tools take about 1–3 weeks and cost under 1/10 of a comparable injection mold.

- **Max. part size**: 2600×1600×600 mm — L × W × H, formed in one piece
- **Max. sheet thickness**: 15 mm — 8–10 mm is typical for housings
- **Tooling lead time**: 1–3 weeks — vs. about 6–10 weeks for a comparable injection mold
- **Tooling cost**: \<1/10 — of a comparable injection mold

- **New-energy experience**: Serving new-energy customers since 2020
- **Large parts, one piece**: Up to 2.6 m
- **Serviceable on site**: Covers designed for the installed layout

## Thermoformed parts for ev, battery & energy systems

New-energy parts that suit thermoforming:

- Charging equipment
- Storage and power units
- Battery equipment
- Battery packaging and handling

### Charger housings and front panels

Large cosmetic parts in one piece; display, connector holster and vents CNC-cut to drawing.

### Storage and power enclosures and service covers

Boxes, lids and side panels split for the installed site and the service direction.

### Battery trays and liners

Battery trays, insulating covers and formed brackets: products we already make in volume (mostly thin gauge).

### Product families for this industry

#### [Housings & enclosures](/en/products/housings)

Enclosures for energy-storage and power units, and charger housings.

#### [Covers & shrouds](/en/products/covers-shrouds)

Service covers for energy-storage and charging equipment.

#### [Panels & fascias](/en/products/panels-fascias)

Charger front panels and fascias.

#### [Trays & liners](/en/products/trays-liners)

Battery trays, insulating covers and formed brackets.

## Examples of thermoformed components

Formed parts from the FUNYO company profile, picked for this industry. Need something similar? Send a drawing or a photo.

![Illustration · EV charger housing](/assets/illustrations/charger.webp)

EV charger housing (Illustration)

![Reference · EV charger housing, installed on site](/assets/ev/charger-housing-1.webp)

EV charger housing, installed on site (Reference)

![Reference · EV charger housings, installed on site](/assets/ev/charger-housing-2.webp)

EV charger housings, installed on site (Reference)

![Power battery housing](/assets/ppt/power-battery-housing.webp)

Power battery housing

![EV battery shell](/assets/ppt/ev-battery-shell.webp)

EV battery shell

![Power battery sealing cover](/assets/ppt/battery-seal-cover.webp)

Power battery sealing cover

![Car battery housing](/assets/cases/battery-housing.webp)

Car battery housing

![New-energy large tray, 2.5 m × 1.1 m](/assets/ppt/large-tray.webp)

New-energy large tray, 2.5 m × 1.1 m

![Formed insulating cover, new energy](/assets/ppt/insulating-cover.webp)

Formed insulating cover, new energy

![Formed tray for new-energy batteries](/assets/ppt/battery-tray.webp)

Formed tray for new-energy batteries

Photos are from FUNYO’s company profile; the caption identifies the thermoformed part. Images labelled “Illustration” are AI-generated. Photos labelled “Reference” show similar products to explain component forms; they are not FUNYO delivery cases.

## Thermoforming compared with other processes

A “housing” does several jobs. What we deliver directly, and what the complete unit must verify:

| Job | Heavy-gauge part delivers | Confirmed on the complete unit |
|---|---|---|
| Appearance and cover | Shape, openings and service access machined to drawing | Installation position and appearance requirements |
| Load and support | Interfaces between housing and frame | Load path, frame and connection design |
| Insulation and flame retardance | Material chosen to the target rating; samples made | Material certificates and system testing |
| Water and sealing | Sealing faces and openings machined to drawing | Seals and the system's protection-rating test |

Splitting the jobs gives material choice and testing a clear boundary.

## Assembly, access and interface design

A cover that opens on the bench may not open between a wall and the next cabinet. We check service access in the installed layout:

### Site boundaries

Walls, neighboring equipment and cable runs go into the layout before cover positions are fixed.

Needed: site layout drawing

### Cover movement

Opening direction, swing range and where a removed cover is set down are tested on the sample.

Confirmed: opening envelope and working space

### Modules and cables

Module replacement paths and cable entry directions are decided together with the enclosure split.

Confirmed: module removal and cable routes

## Sheet materials and project requirements

8–10 mm sheet is typical, up to 15 mm.

- **Outdoor chargers**: A weatherable grade or surface treatment, sourced per project and checked on samples for color change.
- **Flame retardance**: Tell us the target (for example UL 94); we choose a matching flame-retardant grade, confirmed by material certificates and system tests.
- **Indoor storage and power equipment**: ABS is most common; PC where impact resistance is needed.
- **Battery packaging and handling**: Static-dissipative grades; FUNYO has promoted permanent anti-static trays since 2014.

Exact grade, formed condition and end use each need their own confirmation.

## Factory, CNC trimming and inspection

FUNYO started in precision machining in 2004 and has been thermoforming since 2013. Heavy-gauge forming, CNC trimming and dimensional inspection all happen in our Doumen plant, and we machine our own forming tools, so revisions don't wait on outside shops.

![FUNYO heavy-gauge thermoforming machine](/assets/factory/heavy-forming.webp)

Heavy-gauge former: ABS, PC, PVC, PETG and PP sheet; parts up to 2600 × 1600 × 600 mm

![FUNYO 3-axis and 5-axis CNC routers with a formed part on the bed](/assets/factory/cnc-router.webp)

3- and 5-axis CNC routers: trimming, holes and slots after forming; 5-axis for curved surfaces

![Tunnel oven in FUNYO's secondary-processing area](/assets/factory/tunnel-oven.webp)

Tunnel oven for secondary processing: adjustable temperature, airflow and conveyor speed

![Engineer measuring a part on a vision measuring system](/assets/thin-gauge/cmm.webp)

Vision measuring system checks holes and contours; a 3D automatic vision system is also on site

### Facts you can check

- **2004**: Founded; 20+ years of precision machining
- **2005**: Became a tier-1 supplier to Gree
- **ISO 9001 · 14001**: Quality and environmental management certified
- **2024**: Recognized as a High-Tech Enterprise
- **ABS · PET/PS**: Own plant for thermoforming sheet
- **4 hours**: Response to design requests

### Selected long-term customers

Gree Electric, Panasonic, Foxconn, Jabil, Lite-On, TDK, Mitsumi Electric, Mektec, Broad-Ocean Motor, Haojue, JCD, AKM, CYGIA

These relationships cover precision formed trays, CNC parts and other work. Listed in no particular order.

## Lead time from drawing to delivery

Typical timings. Complex parts or special materials get a specific schedule when we quote.

1. **Within 4 hours · Response**: An engineer contacts you to confirm use, size and quantities.
2. **2 working days · Evaluation and quote**: We tell you whether heavy-gauge fits and quote it side by side with injection molding.
3. **About 1–3 weeks · Tooling**: After design review we machine the forming tool in-house.
4. **By complexity · Samples**: Formed, trimmed and drilled, then fitted to your frame or mating parts.
5. **Per order · Production**: Checked against the approved sample for size and finish, then packed and shipped.

[Heavy-gauge thermoforming](/en/capabilities/heavy-gauge-thermoforming) · [CNC trimming and machining](/en/capabilities/cnc-machining-trimming)

## Thermoforming for ev, battery & energy systems: FAQ

Tell us what the part has to do, then send the equipment and site layout; we'll evaluate material, forming and machining.

**Send a drawing. Get an answer in 2 working days.** We respond within 4 hours. Within 2 working days we tell you whether heavy-gauge thermoforming fits, with a side-by-side quote against injection molding. Housing projects of around 3,000 parts a year on an annual supply agreement can apply for a no-tooling-charge evaluation.

- Equipment and part: e.g. DC charger housing and front panel
- Outside dimensions: L × W × H (mm)
- Annual volume and first order: e.g. 800 units/year, first order 50
- Site and ratings: Indoor or outdoor, flame rating, protection rating, service direction
- Contact: Name, company, phone or email

Send drawings or photos to fangyujidian@163.com

STEP, IGES, DWG, PDF or photos. No drawing yet? Send photos and key dimensions.

### FAQ

#### Can thermoforming be evaluated for ev, battery & energy systems at 300–3,000 units per year?

300–3,000 units is a quoting scenario, not a break-even threshold. Compare part size, assembly, material, tooling and unit costs before selecting a process.

#### What size and sheet thickness are available for ev, battery & energy systems?

The maximum single part is 2600 × 1600 × 600 mm, with sheet up to 15 mm. Housings commonly use 8–10 mm sheet. Finished dimensions depend on geometry and trimming allowance.

#### Which sheet grades should I specify for ev, battery & energy systems?

ABS, PC, PVC, PETG and PP can be formed. PC or PETG can be evaluated for transparent parts. PE, weatherable, flame-retardant and antistatic grades are sourced and sampled for the project.

#### How long does tooling for ev, battery & energy systems take?

Forming tooling costs under 1/10 of a comparable injection mold and takes about 1–3 weeks. Comparable injection molds take about 6–10 weeks. Confirm the scope against the drawing and material.

#### What should I send for a 2-working-day thermoforming assessment for ev, battery & energy systems?

Send drawings or photos, dimensions, annual and first-order quantities, assembly interfaces and operating conditions. We respond in 4 hours and provide the applicability assessment and comparison quote in 2 working days.

### Guides

- [EV Charger Cover: Thermoforming, Injection or Metal](/en/guides/ev-charger-enclosure-manufacturing)
- [Large Thermoformed Handling Trays: Specification](/en/guides/large-thermoformed-handling-trays)
- [Thermoforming vs Injection Molding: Break-Even Cost](/en/guides/thermoforming-vs-injection-molding-break-even)

## Contact

Bring us your next big idea. Let’s give it the right shape.

FUNYO / 方宇机电

Building F3, Huamao Road, Qianwu Town, Doumen District, Zhuhai, Guangdong, China

Tel: +86-0756-6330998

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Last updated: 2026-10-22