Mass Production of Custom 1.5mm Carbon Steel Battery Boxes
Openex Large Metal Fab recently partnered with an overseas client to mass-produce customized, high-quality battery box enclosures for a large-scale Renewable Energy project. Marking a successful milestone, our team seamlessly cleared rigorous client inspections and delivered the first 100+ sets flawlessly, initiating the mass delivery phase for a total contract of over 500 units.
The Engineering Challenge
Fabricating battery enclosures for energy storage requires stringent cosmetic and dimensional standards. Fabricated from 1.5mm high-quality carbon steel, the client presented a distinct and demanding set of manufacturing requirements:
- ✕ Zero-Defect Surface Finish: No grinding marks were allowed to be visible on the metal post-powder coating.
- 📏 Precision Coating: Electrostatic powder coating membrane thickness had to be strictly controlled within an extremely tight range of 80～120μm.
- ✓ Strict Dimensional & Weld Consistency: Extreme dimensional accuracy across robotic weld seams.
The Openex Solution & Process
To balance uncompromising quality with a tight delivery schedule, Openex established a dedicated project task force. By leveraging our massive engineering ecosystem—specifically our 150-meter fully automated, digital flexible smart sheet metal production line—we executed the entire fabrication process in-house.
Comprehensive Production Workflow:
Prototyping played a crucial role in eliminating manufacturing defects. We performed multiple trial runs, inspecting variables via large-scale Coordinate Measuring Machines (CMM) and advanced membrane thickness gauges. By instituting strict scientific quality gates at each processing node, the material utilization rate increased, cycle times shortened, and flawless aesthetic continuity was achieved without a single grinding mark visible.
Scaling New Heights: Openex is equipped to produce high-volume, critical structural components for Renewable Energy platforms, Electric Buses, Port Transfer Vehicles, Commercial EV Trucks, Power Plant Energy Storage Systems, and EV Charging Piles worldwide.
