With the continuous increase in the penetration rate of new energy vehicles, electric vehicle battery tray injection molds are facing unprecedented demands for technological upgrades. Traditional metal trays are gradually being replaced by lightweight plastics/composite materials, and injection molding processes have become the mainstream path. In 2025-2026, the new requirements for battery tray molds focus on lightweighting, safety, thermal management, and high integration, helping to improve vehicle range and optimize costs. As a professional injection mold manufacturer with years of experience in new energy vehicle projects, we have successfully delivered multiple high-performance battery tray mold solutions.
- Balancing Lightweighting and Structural Strength The battery tray needs to support battery packs weighing hundreds of kilograms while achieving 30%-50% weight reduction. The mold must support injection molding of long glass fiber reinforced PP (LGF-PP), flame-retardant STAMAX™, or continuous fiber composite materials. Design requirements include high-precision CNC machining, multi-cavity parting, precise insert positioning, and integrated built-in cooling channels for one-piece forming, ensuring high rigidity and impact resistance even under thin walls (1.5-3mm).
- Upgraded Extreme Safety and Flame Retardant Standards Thermal runaway protection has become the core: the mold must be compatible with UL94 V-0 (or even higher) flame-retardant materials, combined with intumescent flame retardants or intumescent coatings. Cavity surface treatment is upgraded to mirror level to avoid defects causing safety hazards; at the same time, EMI shielding and electrical insulation functions are integrated to meet stringent regulations such as GB 18384-2020.
- Thermal Management and Process Innovation The tray needs to integrate water cooling/thermal channels. The mold adopts hot & cold molding technology (heating the mold to 80-130℃ before injection to improve resin flowability and eliminate weld lines; rapid cooling to 60-70℃ after packing to reduce deformation). Large two-platen injection molding machines (such as FA3550T level) have become standard, supporting large-size (>2000mm) precision molding with clamping accuracy ≤0.1mm.
- Sustainability and Intelligent Trends The application of environmentally friendly recyclable materials is increasing, and mold design emphasizes functional integration (such as wiring harness routing, metal insert overmolding) to reduce secondary processing. Intelligent molds are equipped with sensors for real-time monitoring, improving predictive maintenance and production efficiency.
ATC-mould specializes in custom electric vehicle battery tray injection molds, providing one-stop services from CAE analysis to trial molding and mass production. We use high-quality steels such as NAK80 and STAVAX ESR to ensure mold lifespan and surface quality.