Quick Answer
A Li-Ion battery box is a precision sheet-metal enclosure that houses lithium-ion cells, BMS electronics and thermal management components for electric vehicles and energy storage systems. KM Engineering manufactures custom Li-Ion battery boxes in Faridabad from 1.6–3 mm CRCA or SS 304 steel, TIG-welded and IP54/IP65 rated, with a typical lead time of 12–18 days and MOQ starting at 10 units.
What Is Li-Ion Battery Box Manufacturer?
A Li-Ion battery box is the structural enclosure that physically protects lithium-ion battery cells, the Battery Management System (BMS), busbars, connectors and thermal components inside an electric vehicle, e-rickshaw, inverter or energy storage system. Unlike a generic sheet-metal box, a Li-Ion battery enclosure must meet electrical isolation, thermal dissipation, ingress-protection (IP54/IP65/IP67) and crash-performance requirements simultaneously.
KM Engineering fabricates custom Li-Ion battery boxes for Indian EV OEMs in the 2W, 3W and light 4W segment, as well as for stationary solar + BESS (Battery Energy Storage System) applications. Each unit is built to the customer's cell layout — typically 48 V / 51.2 V / 72 V packs using 18650, 21700 or prismatic LFP cells — from Cold-Rolled Close-Annealed (CRCA) steel, stainless steel SS 304, or optionally aluminum 5052 for weight-sensitive applications.
Our battery boxes are manufactured in-house using fiber-laser cutting, CNC press-brake bending, robotic TIG/MIG welding and a 7-tank pre-treatment powder-coating line. We ship to 25+ OEM clients across Haryana, Delhi-NCR, Rajasthan, Uttar Pradesh and Gujarat under an ISO 9001-aligned quality system with full material traceability and PPAP-style documentation for OEM buyers.
Detailed Specifications
Full technical specifications for Li-Ion Battery Box Manufacturer — material grades, tolerances, process capabilities, and standards compliance.
| Specification | Value / Description |
|---|---|
| Material Grade — Steel | IS 513 CRCA, IS 6911 SS 304 / SS 316 |
| Material Grade — Aluminum (optional) | AA 5052 H32 / AA 6061 T6 |
| Sheet Thickness | 1.6 mm / 2.0 mm / 2.5 mm / 3.0 mm (application-specific) |
| Maximum Single-Piece Cut Size | 3000 × 1500 mm (fiber-laser bed) |
| Cutting Tolerance | ± 0.1 mm (fiber-laser, parts ≤ 500 mm) |
| Bending Tolerance | ± 0.5° angular, ± 0.2 mm linear (CNC press brake) |
| Welding Process | TIG (GTAW) for stainless / aluminum; MIG (GMAW) for CRCA |
| Weld Leak Integrity | Dye-penetrant test on critical seams; leak-test optional (DPT / air-decay) |
| Surface Pre-Treatment | 7-tank phosphating line (degrease → rinse → phosphate → rinse → passivate → rinse → DI) |
| Powder Coating Thickness | 60–80 µm (exterior), 40–60 µm (interior cavity) |
| Standard Color | Matte Black RAL 9005 / Grey RAL 7035 (custom RAL on request) |
| Ingress Protection (Standard) | IP54 — dust-protected, splash-resistant |
| Ingress Protection (Upgrade) | IP65 (gasket + controlled vent), IP67 (gasket + welded feed-throughs) |
| Gasket Material | Closed-cell EPDM / silicone foam, 3–6 mm |
| Thermal Provision | Optional cold-plate mounting cutouts, vent louvres, fan apertures |
| EMI/EMC Provision | Full metal envelope acts as Faraday shield; conductive gasket available |
| Mounting Interface | M6/M8 PEM studs / weld-nuts as per customer drawing |
| Typical Weight (empty, 48V 30Ah pack size) | 6–9 kg (CRCA 2.0 mm) |
| Dimensional Tolerance (overall) | IT-13 general; critical features as per drawing |
Manufacturing Process
How KM Engineering fabricates Li-Ion Battery Box Manufacturer — step-by-step process from drawing review to dispatch.
Drawing & DFM Review
Customer shares 2D drawings (PDF/DWG) and 3D model (STEP/IGES). Our design engineers run a Design-for-Manufacturability review — verifying bend reliefs, weld access, stud placement and tooling feasibility — and return a DFM report within 48 hours.
Nesting & Fiber-Laser Cutting
Approved flat patterns are nested for material utilization (target > 75%) and cut on our 4 kW fiber-laser (bed 3000 × 1500 mm). Cutting tolerance ± 0.1 mm on parts up to 500 mm, kerf ~0.15 mm.
CNC Press-Brake Bending
Cut blanks are bent on CNC press-brakes with custom tooling. Bend sequence is programmed to avoid interference; angular tolerance ± 0.5°.
Welding & Fixturing
Parts are clamped in product-specific jigs. TIG welding for SS/aluminum panels, MIG for CRCA structure. Weld-nuts and PEM studs inserted pre-weld. Inter-pass temperature controlled to minimize distortion.
Inspection — In-Process
Dimensional check on CMM-layout fixtures; flatness and diagonal checks; dye-penetrant test on sealed seams; continuity/earth-bond test for conductive frames.
7-Tank Pre-Treatment
Degrease → rinse → phosphating → rinse → passivation → rinse → DI rinse. Surface prepared for powder adhesion; phosphate coating weight 2–4 g/m².
Powder Coating & Curing
Electrostatic powder spray (epoxy-polyester). Cured in paint tunnel at 180–200 °C for 15–20 minutes. Cross-hatch adhesion test (ASTM D3359) per batch.
Assembly — Gaskets, Hardware, Labels
EPDM/silicone gaskets applied; M6/M8 PEM studs verified; product-ID plate riveted; mounting hardware kitted per customer BOM.
Final QC & Packaging
100% visual QC; dimensional sampling per AQL 1.5 or customer PPAP; individual bubble-wrap + carton; bulk stretch-wrap on pallets; dispatch documentation (DC + GST invoice + material test certificate).
Request a Quote for Li-Ion Battery Box Manufacturer
Share your drawings or requirements — we respond within 24 hours with a DFM review and priced offer.
Standards & Compliance
KM Engineering manufactures Li-Ion Battery Box Manufacturer in alignment with the following Indian and international standards:
- AIS-156 — Automotive Industry Standard for L-category EVs (battery-safety alignment)
- IS 513 — CRCA steel sheet grade
- IS 6911 — Stainless steel sheet grade
- IEC 60529 — IP protection classification (IP54/IP65/IP67)
- ASTM D3359 — Cross-hatch adhesion test for coatings
- ISO 9001:2015 — Quality Management System alignment
- REACH/RoHS — Powder coating and raw material compliance
Industries & Applications
Li-Ion Battery Box Manufacturer by KM Engineering is used across multiple Indian industries. Below are typical buyers, their applications, and why they choose us:
EV 2-Wheeler OEMs
Application: Swap-able 48 V / 60 V battery boxes for electric scooters and motorcycles
Why KM: Light-weight CRCA construction (6–9 kg empty), IP65-ready, robust handle/lock mounting for repeated swap cycles
EV 3-Wheeler & E-Rickshaw OEMs
Application: Under-chassis 48 V / 60 V / 72 V traction battery housings
Why KM: 2.0–3.0 mm CRCA with reinforcement ribs — survives Indian pothole loads; cost-optimized for competitive 3W BOM
Stationary BESS / Solar Hybrid
Application: Indoor rack-mount and outdoor cabinet battery enclosures for residential and telecom ESS
Why KM: SS 304 or thicker CRCA with IP65 outdoor-rated finish; provisions for BMS, breakers and vent louvres
Telecom & Critical Infrastructure
Application: Backup lithium battery cabinets for cell towers and edge data centers
Why KM: IP54 outdoor cabinet with thermal venting and EMI-shielded enclosure; lockable door with multi-point latch
Industrial AGVs & Material-Handling
Application: Traction battery enclosures for automated guided vehicles and electric forklifts
Why KM: Rugged 2.5–3 mm construction, heavy mount brackets, vibration-resistant gasketing
Customization Options
Every Li-Ion Battery Box Manufacturer we fabricate is made to the customer's drawing or specification. Customizable aspects include:
- Cell layout — 18650 cylindrical, 21700 cylindrical, prismatic LFP (cut-outs + busbar tabs as per cell drawing)
- Voltage and pack size — any OEM specification from 24 V up to 96 V, capacity 1.5–15 kWh
- Ingress protection — IP54 / IP65 / IP67 with matched gasket, vent and cable-gland provisions
- Material — CRCA, SS 304, SS 316, aluminum 5052, mild steel with e-coat
- Thermal — mounting bosses for cold-plates, fan cut-outs, louvred passive vents, phase-change material pockets
- Finish — any RAL shade, textured finish, anti-static coating, chemical-resistant epoxy
- Branding — screen-printed or laser-etched logos, pad-printed nameplates, riveted metal ID plates
- Hardware — M6/M8 PEM studs, weld-nuts, cam locks, hinge types, handle styles, strap provisions
- Connector cut-outs — Anderson, XT-90, AMP, JST or customer-specified cable-gland layouts
Quality Assurance & Testing
Each Li-Ion Battery Box Manufacturer undergoes the following QC steps as part of our ISO 9001:2015-aligned quality system:
- First-Article Inspection (FAI) — full dimensional report before series start
- In-process dimensional check at cutting, bending and welding stations
- Dye-penetrant test (DPT) on sealed weld seams
- Air-decay leak test (optional) for IP65/IP67 claims
- Salt-spray test (ASTM B117, 240–500 hours) on coated samples — per batch / per quarter
- Cross-hatch coating adhesion test (ASTM D3359) per production batch
- Coating thickness measurement by magnetic/eddy-current gauge
- Earth-bond continuity test (< 0.1 Ω) for conductive frames
- Visual QC at 100% units; packaging inspection per AQL 1.5
How We Compare
Here is how KM Engineering's Li-Ion Battery Box Manufacturer compares against alternative supplier options available to Indian buyers:
| Criterion | KM Engineering | Branded National Supplier | Unorganized Local Fabricator |
|---|---|---|---|
| Typical Price per Unit (48V, 30Ah size) | INR 1,400 – 2,200 (CRCA) | INR 2,600 – 3,800 | INR 1,900 – 2,600 |
| Material Certification | TC + traceability on request | Mill TC available | Usually not provided |
| Minimum Order Quantity | 10 units (prototype) | 100+ units | 1–5 units |
| Lead Time — Prototype | 12–15 days | 4–6 weeks | 20–30 days |
| IP Rating Support | IP54 / IP65 / IP67 | IP65 standard | IP54 typical |
| Customization Flexibility | Full drawing-to-part | Catalog variants only | Limited |
| Quality Documentation | FAI + PPAP-style on demand | Standard QC report | Minimal |
Ordering & Lead Time
Frequently Asked Questions
What sheet thickness do you recommend for a Li-Ion battery box?
For EV 2W and 3W applications, 2.0 mm CRCA is the most common choice — it balances weight (typically 6–9 kg empty for a 48 V / 30 Ah box) with crash and vibration durability. Heavy-duty 3W traction packs and stationary BESS typically use 2.5–3.0 mm CRCA or 1.5–2.5 mm SS 304. For weight-critical applications, 2.0–2.5 mm aluminum 5052 is available.
Do you manufacture to AIS-156 requirements?
Our battery boxes are manufactured with AIS-156 alignment in mind — which includes mechanical integrity, IP rating, and electrical isolation provisions. Full AIS-156 certification is a pack-level test (battery + BMS + cells + enclosure together) performed by the OEM at certified labs such as ARAI or ICAT; we supply the enclosure with documentation that supports the OEM's certification testing.
What is the minimum order quantity?
MOQ is 10 units for a prototype batch. For series production pricing we recommend orders of 50 units or more. For very low-volume projects (R&D, pilot runs) we also accept 1–5 unit special orders with sample-batch pricing.
Can you provide IP65 or IP67 rated enclosures?
Yes. IP54 is our standard specification. IP65 is achieved through closed-cell EPDM or silicone gasketing plus controlled venting (hydrophobic breather valves). IP67 requires fully welded or gasketed cable feed-throughs and pressure-decay leak testing. IP65/IP67 typically adds 8–15 days to lead time and 12–20% to unit cost.
What is the typical lead time for a first prototype?
From receipt of approved drawings, we deliver a first prototype in 12–15 working days including DFM, cutting, bending, welding, coating and QC. Subsequent pilot batches (10–50 units) ship in 2–3 weeks. Series production (200+ units per lot) ships in 3–4 weeks.
Do you supply with material test certificates?
Yes. We maintain material traceability and provide mill test certificates (TC) on request for CRCA, SS 304 and aluminum 5052. For PPAP-grade supply we provide a full documentation set including FAI, coating thickness readings, salt-spray report and material TCs.
Can you do powder coating in custom RAL colors?
Yes. Standard colors are matte black (RAL 9005) and grey (RAL 7035) with short lead times. Custom RAL shades, textured finishes, and chemical-resistant epoxy coatings are available with a 5–7 day material-procurement lead-time addition.
Do you work with startups and early-stage EV companies?
Yes. A significant portion of our customer base is early and mid-stage EV startups and 3W OEMs. We support iterative DFM, offer low MOQ prototyping, and scale directly from prototype → pilot → series without a supplier change.
What is your quality management system?
We operate an ISO 9001:2015-aligned quality system with documented procedures for incoming material, in-process inspection, final QC, and non-conformance handling. Larger OEM customers receive PPAP-style documentation on request.
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