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Stamped and Bent Sheet Metal Battery Cover Manufacturing

Stamped and Bent Sheet Metal Battery Cover Manufacturing

The HPS Custom EV Battery Module Top Cover is a structural shielding component designed for New Energy Vehicles (NEV) and Energy Storage Systems (ESS). 

 

Fabricated from Aluminum Alloy (3003/5052) or Galvanized Steel, this part functions as a protective barrier for internal busbars and battery cells. 

 

HPS manufactures this component using precision stamping and CNC forming processes to ensure dimensional stability and burr-free edges, meeting strict IATF 16949 automotive standards.

  • Material :

    Hot-Dip Galvanized Steel (SGCC) / Electro-Galvanized (SECC)
  • Thickness :

    1.0mm – 3.0mm (Thicker gauge for pressure resistance)
  • Surface Treatment :

    Galvanized / Powder Coating
  • Process Involved :

    Laser Cutting, CNC Bending, Riveting, Assembly

Product Overview

 

This stamped and bent sheet metal battery cover is designed to protect battery components while ensuring precise fit and structural stability. Manufactured through progressive stamping and precision bending processes, it meets the requirements of consistent quality and reliable performance in industrial and electronic applications.

 

The battery cover can be produced using materials such as cold-rolled steel, stainless steel, or aluminum, depending on strength, weight, and corrosion resistance requirements. Accurate tooling and controlled tolerances ensure compatibility with battery assemblies and facilitate efficient installation in mass production environments.

 

Surface treatments including powder coating, plating, anodizing, or passivation are available to enhance durability and environmental resistance. The product supports customization in dimensions, material thickness, hole positions, and structural features, making it suitable for OEM and custom battery system projects across various industries.

 

SECC Electro Galvanized Steel Custom Bracket     Galvanized Steel Electronic Enclosure Sub Assembly

 

Key Features & Advantages

 

Automotive Grade Safety: The manufacturing process includes automated deburring and tumbling to achieve 0.00mm visual burrs. This prevents sharp edges from damaging the battery insulation film (PET), a critical requirement for high-voltage safety.

Precision Geometric Control: Using Trumpf TruBend 5230 equipment, HPS controls the straightness and camber of long-span covers within ±0.5mm/meter. This ensures a flush fit when assembled onto the battery module frame.

Integrated Locking Features: The design incorporates progressive die-stamped tabs and interlocking hooks. These integrated features replace separate fasteners, reducing the assembly time for battery pack manufacturers.

Lightweight Material Optimization: We utilize lightweight Aluminum alloys (AL3003/AL5052) which offer high thermal conductivity and corrosion resistance, essential for thermal management in EV battery packs.

Scalable OEM Production: Our facility supports both prototyping (laser cutting) and mass production (hard tooling/stamping), ensuring consistent quality from pilot runs to high-volume delivery.

 

 

Product Specifications

 

Component Name
Battery Module Top Cover / Busbar Shield
Material Options
Aluminum (3003, 5052), Steel (SGCC, SECC)
Thickness Range
0.8mm – 2.0mm (Customizable)
Fabrication Method
CNC Laser Cutting, NCT Punching, Stamping
Tolerance Standard
ISO 2768-m (General), ±0.1mm (Critical features)
Surface Treatment
Cleaning, Passivation, Anodizing, Insulation Coating
Burr Standard
Strict Burr-Free Requirement (Safety Critical)
Certification
IATF 16949:2016, ISO 9001:2015

 

 

Applications

 

  • Prismatic Cell Modules: Top structural protection for prismatic Lithium-ion battery modules used in Electric Vehicles (EV).
  • Battery Pack Busbar Routing: Insulated covers ensuring physical separation between high-voltage copper busbars and the external enclosure.
  • Energy Storage Racks (ESS): Safety shielding for commercial and industrial grid-scale battery systems.
  • Hybrid Electric Vehicles (HEV): Compact, lightweight covers for hybrid battery sub-assemblies.

 

Manufacturing & Quality Assurance

 

All products are manufactured in our 30,000㎡ sheet metal facility equipped with advanced CNC punching, AMADA fiber laser cutting, automated welding robots, and automatic powder coating lines. Strict quality control is implemented under ISO9001 and ISO14001 management systems.

Company Strength

 

Xiamen Huapusheng Sheet Metal Manufacturing Co., Ltd. specializes in power control equipment and precision sheet metal fabrication. With 200+ employees, 36 engineers, and 32 patents, we serve global clients in the power, communication, and industrial sectors.

 

Xiamen Huapusheng Sheet Metal Manufacturing Co., Ltd.

 

FAQ

 

Q: Why is burr control critical for EV battery covers? 

A: Burr control is critical because sharp metal edges can puncture the thin insulation layers of battery cells, causing short circuits or thermal runaway. HPS utilizes specialized deburring processes to ensure safe, smooth edges for all battery components.

 

Q: What materials are best for battery module top plates? 

A: Aluminum Alloy 3003 or 5052 is typically preferred for battery module top plates due to its lightweight properties, good thermal conductivity, and corrosion resistance, which helps improve the overall energy density of the battery pack.

 

Q: Can HPS manufacture battery covers to automotive standards? 

A: Yes, HPS is an IATF 16949 certified manufacturer, qualified to supply Tier 1 automotive customers with PPAP (Production Part Approval Process) documentation and strict quality control.

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