A leading battery technology manufacturer needed rugged, lightweight enclosures to protect battery modules, BMS electronics and wiring across both mobile and stationary energy storage applications. We delivered 1,200 precision aluminum housings with IP54 sealing, active thermal management and consistent batch quality.
Precision-engineered battery pack enclosures built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
Electric mobility and renewable energy storage are driving explosive demand for reliable, long-life battery systems. In 2026, a leading battery technology manufacturer launched a full customization program for its next-generation battery pack line, targeting both vehicle applications and stationary energy storage cabinets.
The enclosure had to shield lithium-ion battery modules, the battery management system (BMS) and all low-voltage wiring while surviving vibration, dust and occasional moisture. The customer needed a manufacturing partner that could combine precision sheet metal, thermal design and consistent volume production.
The customer’s previous supplier struggled with three recurring problems:
On top of that, batch-to-batch dimensional drift meant some enclosures would not accept the customer’s standard modules without rework.
We faced four interlocking engineering challenges:
Our engineering team rebuilt the enclosure around a multi-layer ventilation strategy. Precision-punched honeycomb holes on the top and side panels draw cooling air through the pack, while removable washable dust filters block ingress. Finite element analysis (FEA) optimized internal reinforcing ribs, raising structural stiffness by 25% without adding weight.
The first 1,200-unit batch shipped 7 days ahead of the 45-day schedule and passed every dimensional, IP54 and thermal test with a 100% first-pass rate.
SanJun Hardware understood both our thermal and our sealing requirements from the first DFM review. The enclosures fit our standard modules perfectly and the on-time delivery kept our production line running. We have appointed them as our exclusive sheet metal enclosure partner for the full battery pack line.
Eight reasons global brands partner with SanJun Hardware for precision sheet metal fabrication
Quality-managed production with documented processes and full traceability at every stage.
Streamlined scheduling and capacity planning ensure your orders ship when promised.
Expert design-for-manufacturing review at no cost –optimize your design before production.
Sheet metal ±0.1mm and CNC machining ±0.01mm –consistent accuracy across every batch.
From laser cutting and bending to welding, coating and assembly –all under one roof.
CMM inspection, coating adhesion tests, and 100% final inspection before every shipment.
Prototypes from 1 unit to production runs of 10,000+ –scalable capacity to match your needs.
Work directly with our engineering team –fast responses, clear updates, no middlemen.
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