Automotive EV Battery Enclosure HP-RTM System in China

Illustration notice. Process illustrations are not verified photographs of this installation.

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Haifeng successfully engineered and commissioned an automated High-Pressure Resin Transfer Molding (HP-RTM) production system for a leading Tier-1 Chinese EV battery enclosure supplier, cutting battery tray weight by 40% with a UL94 V-0 material flammability classification. Battery fire containment and electrical safety are separate finished-enclosure and battery-system validation requirements. The delivery encompassed a specialized high-output HP-RTM resin dosing skid, multi-channel mold vacuum modules, dynamic thermal conditioning units, and digital process coordination interfacing with the client's large-bed composite press.

Prior to commissioning, the manufacturer assembled battery lower trays via aluminum extrusion welding. Metallic trays suffered from excessive tare weights, poor anti-corrosion endurance under road de-icing salts, and severe short-circuit risks that required expensive secondary dielectric coatings. The customer required an industrial-scale manufacturing system capable of injecting flame-retardant polyurethane precursors into multi-layered continuous glass fiber preforms across an expansive 2-meter footprint, eliminating dry spots and compressing demold cycles down to 4 minutes.

Operational since March 2026 on a continuous two-shift production schedule across a 320 m² workcell, the installation provides reliable high-volume composite processing. By utilizing Haifeng's closed-loop Ratio Lock flow algorithms and high-velocity impingement heads, the client reliably manufactures structural, flame-retardant composite battery trays complying with strict automotive safety regulations.

Planning a related production line

Use this record as an application-specific reference. Reinforcement introduction, resin chemistry, tooling, consolidation and qualification differ between RIM, LFI, SMC and HP-RTM. A result from one process does not establish performance of another.

Production brief for technical discussion

Provide a finished-product drawing or sample, material data, target output, automation needs and factory conditions. Haifeng will review the process, equipment interfaces and acceptance plan for your own production goals.

Concept illustration — not a photograph of delivered equipment or a customer installation.

The 40% reduction refers to this project’s structural tray compared with its welded aluminum assembly baseline, not total vehicle weight or every future tray design. The stated UL94 V-0 result applies to the tested material construction and conditions. Pack thermal propagation, electrical safety, sealing and impact performance are separate validation tasks for the relevant assembly.

Haifeng deployed a high-output HP-RTM dosing platform engineered for wide-span cavity filling and rapid-curing flame-retardant formulations, achieving end-to-end composite consolidation within 4 minutes:
1. High-Output Stoichiometric Ratio Lock: Heavy-duty axial displacement pumps meter resin and hardener at large volumes with ±0.5% precision, ensuring full wet-out across wide multi-layer preforms.
2. Multi-Channel Vacuum Management: High-capacity vacuum skids evacuate the massive tool cavity to <10 mbar within seconds, eliminating microscopic porosity traps.
3. Multi-Zone Thermal Balancing: Dynamic TCU loops maintain upper and lower mold platen temperatures within ±0.8°C, preventing flow front chilling across long flow paths.
4. Self-Cleaning High-Pressure Injection Head: An industrial impingement mixing head executes rapid 0.3-second mechanical clean cut-offs without chemical solvent flushes, maximizing continuous uptime.