Over-Molded Structural Thermoplastic Hybrid EV Battery Enclosure

SABIC – in collaboration with ENGEL, Forward Engineering, and other value chain contributors – has developed a high-voltage EV battery pack enclosure system as a proof of concept for next-generation applications. Developed following a study of an existing, metal-intensive production design, the enclosure system features a hybrid construction consisting of a cover, tray, and metallic underbody panel. The cover and tray are molded with flame-retardant, fiber-filled thermoplastic resin (STAMAX™ 30YH570), with the cover over-molded with continuous fiber-reinforced thermoplastic composite laminates (organosheets). The tray integrates 37 metal inserts, structural ribs, and five fasteners into a single-molded component. This advanced design is enabled by SABIC’s BLUEHERO™ electrification initiative and MEGAMOLDING™ platform and realized using ENGEL’s turnkey production cell – centered on the duo 5500 combi M two-platen injection molding machine. This project demonstrates the feasibility of scalable, lightweight, and highly integrated battery enclosure manufacturing. By combining structural performance, flame retardancy, and design.