The automotive roll forming EV tray is engineered to be the structural backbone of electric vehicles. Utilizing Ultra-High-Strength Steel (UHSS) and Advanced High-Strength Steel (AHSS), we manufacture high-precision battery trays that offer maximum protection for battery cells while drastically reducing overall vehicle weight.
The roll-forming process allows for the creation of complex, deep-channel profiles with integrated stiffening ribs. This design optimizes the strength-to-weight ratio, providing critical impact protection against side pole crashes and underbody strikes. Unlike traditional aluminum die-casting, our process eliminates porosity issues, ensures superior dimensional stability, and significantly lowers tooling costs for high-volume production.
| Manufacturing Process | Continuous Cold Roll Forming + In-line Piercing + Laser / HF Welding (seam closure) + Cut-to-length + Assembly Welding |
| Material Grade | DP590 / DP780 / DP980 (Dual Phase), HC340LA–HC420LA (HSLA), optional DP1180 / Martensitic MS1300 for ultra-lightweight designs |
| Yield Strength (Rp0.7) | 340 – 980 MPa (material dependent) |
| Tensile Strength (Rm) | 590 – 1300 MPa (AHSS grades) |
| Material Thickness | 0.8 mm – 2.0 mm (frame/rails); 0.6 – 1.2 mm (base plate) |
| Cross Section Types | Hat-section (┐─┌), U-channel, C-section, Closed rectangular (perimeter beam after laser welding) |
| Typical Overall Dim. | Length: 800 – 2000 mm / Width: 500 – 1400 mm / Height: 80 – 180 mm (custom per OEM drawing) |
| Dimensional Tolerance | Profile Height/Width: ±0.15 mm / Length: ±0.5 mm / Straightness: ≤0.3 mm / 300 mm |
| Minimum Bend Radius | R_min ≥ 1.5 × t (per VDA 239-100 for AHSS) |
| Surface Treatment | Electro-galvanized (EG, Zn 20–45 g/m²/side), Hot-Dip Galvanized (HDG), or Zinc-Nickel (Zn-Ni 8–12 µm) + E-coat / Powder Coating |
| Weld Type | Continuous laser butt weld (penetration ≥85%) or resistance spot weld for sub-assemblies |
| Sealing / IP Rating | Compatible with IP67/IP6K9K sealing gaskets when mated with upper cover |
| Applicable Standards | IATF 16949, ECE R100 (side & bottom impact), GB 38031-2020, SAE J2464, VDA 239-100 (formability) |
| Design Life | 10–15 years / ≥150,000 km vehicle service life |
Multi-Material Compatibility: Supports steel, aluminum, and composite cell configurations.
Integrated Cooling: Optional integration of cooling plate channels within the roll-formed profile.
Sealing Performance: Precision edges ensure perfect sealing with gaskets to meet IP67/IP6K9K ratings.
Ground Clearance: Low-profile designs maximize battery capacity without sacrificing vehicle clearance.
We are looking forward to working with you. Please feel free to contact us if you have any inquiry.
