Flame-retardant, lightweight, IP67-rated. Density 1.03 g/cmΒ³, UL94 HB / V-0 grades available. Battery pack cases, inverter housings, BMS enclosures β STEP file in β quote in 24h.
Engineered for thermal safety, weight reduction & design flexibility
UL94 HB and V-0 grades available. Self-extinguishing formulations. Critical for battery thermal runaway containment.
Density 1.03 g/cmΒ³. Every kg saved = more range. PDCPD enclosures reduce pack weight by 8β12 kg vs steel cases.
Integrated sealing grooves for gaskets. Dust-tight, waterproof to 1m depth. No secondary sealing operations needed.
HDT 95β110Β°C. Service range β60 to 205Β°C. Withstands under-hood and battery pack operating temperatures.
60β80% cheaper than aluminum die-casting tooling. Viable from 50 pcs. Fast iteration for new EV platforms.
Cooling channel inserts, busbar mounts, BMS bracket bosses β all molded in. No welding, no machining, no assembly.
Real PDCPD EV enclosures molded by HongFox β no renderings
400V pack, 1200Γ600mm, delivered to Netherlands
IP67 rated, integrated cooling channels
Compact, EMI-shielded, snap-fit design
Outdoor-rated, UV-stable, tamper-resistant
Integrated gasket groove, threaded inserts
Full pack assembly, crash-tested
Tested per GB/T, ISO, and UL standards. Full dimensional report with every batch.
| Property | Value | Standard |
|---|---|---|
| Density | 1.03 g/cmΒ³ | GB/T 1033 |
| Tensile Strength | 51β60 MPa | GB/T 1040 |
| Flexural Modulus | 2.0β2.2 GPa | GB/T 9341 |
| Unnotched Impact | 25β80 kJ/mΒ² | GB/T 1043 |
| HDT (1.8 MPa) | 95β110 Β°C | GB/T 1634 |
| Service Temp | β60 to 205 Β°C | β |
| Water Absorption (24h) | <0.1% | GB/T 1034 |
| Flame Class | UL94 HB / V-0 (FR grade) | UL94 |
| Dielectric Strength | 15β20 kV/mm | IEC 60243 |
| Parameter | Range |
|---|---|
| Mold Pressure | <1 MPa |
| Wall Thickness | 2β12 mm (3β5mm typical for packs) |
| Max Part Size | Up to 2 m+ in single shot |
| Cure Time | 30β180 s injection + 5β20 min demold |
| Mold Material | Aluminum (prototype) / Steel (production) |
| IP Rating | IP54 / IP65 / IP67 (with gasket) |
PDCPD vs Aluminum vs Steel vs ABS β EV enclosure material comparison
From CAD file to finished EV enclosure β fully in-house
Transparent pricing structure β no hidden fees
50 pcs
Aluminum mold Β· 18β25 days Β· Ideal for validation
200β500 pcs
Aluminum mold Β· 25β30 days Β· Pilot EV programs
1,000β5,000 pcs
Steel mold Β· 25β35 days Β· Serial EV production
CNC Prototype
5β7 days Β· Validate fit & thermal performance
Where our PDCPD EV enclosures are deployed today
Quick answers to the questions we hear most from EV engineers
PDCPD is 40% lighter than aluminum (1.03 vs 2.7 g/cmΒ³), costs 60β80% less in tooling, and offers better impact absorption. Aluminum wins on thermal conductivity and very high-volume production (>10,000 pcs/year). For low-to-mid volume EV programs, PDCPD is the smarter choice.
We offer UL94 HB as standard and UL94 V-0 on request. Both use halogen-free flame retardants. Self-extinguishing time <10s for V-0 grade. Full UL test reports available upon request.
Yes. We mold integrated sealing grooves for EPDM or silicone gaskets. Every enclosure is water-tightness tested before shipment. IP67 (1m water immersion for 30 min) is our standard rating with proper gasket installation.
Yes. We can mold in cooling plate inserts (aluminum or copper) and create internal channels for liquid cooling. The low-pressure RIM process won't damage delicate inserts. We also offer thermal interface material application.
Approximately 30 days including aluminum mold fabrication and first-article approval. For repeat orders with approved molds, batches ship in 18β25 days from order confirmation. Steel molds for 1,000+ units take 4β6 weeks but enable faster cycle times.
Our process is ISO 9001:2015 certified. PDCPD material meets REACH and RoHS compliance. For automotive qualification (IATF 16949), we can work within your PPAP process and provide full material traceability documentation.
Yes. We routinely sign mutual NDAs before receiving battery pack designs. Your EV architectures remain your property β we never reuse or resell custom mold designs. Mold ownership transfers to you upon project completion.
Send your battery pack / inverter / BMS design files. Quote within 24 hours. NDA available.
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