EV BATTERY ENCLOSURES LUTTERWORTH
Proven Machined, Welded & Hybrid Aluminium Solutions
Universal Fabrications has over 45 years of experience serving Lutterworth and has become a trusted manufacturing partner in the EV sector, delivering complex aluminium battery enclosure solutions. From full CNC-machined housings to hybrid assemblies combining machined and welded components, we provide complete support from design through to scalable production.
If you have a need for battery enclosure solutions, call us today on 02476 370 272
or email@universalfabrications.com
Manufacturing Capabilities & Services
Design for Manufacture
Early design input to optimise cost, weight, and manufacturability
Our comprehensive service combines design expertise with practical manufacturing insights, ensuring seamless integration from concept to production. With a focus on efficiency, quality, and cost-effectiveness, we collaborate to bring customer concepts to life with precision and reliability.
CNC Machining
Precision machining of complex parts and sealing surfaces, up to. 2m x 2m and 10T handling
Through our multi 3,4 & 5 Axis CNC milling machines, we are able to machine the most complex of profiles, pockets and contouring to industry leading tolerance levels. With our large bed machines, we can mill parts up to a size of 2 metres by 2 metres. Our largest machine can even 5 axis mill a 1 metre cube and lift it off with our cranes which can carry loads of up to 10 tonnes.
From a turning point of view our CNC Lathes, Turn Mill and Swiss Lathe can turn parts up to 500mm in diameter and can machine up to 7 axis. This turning and milling capability coupled with our tooling and material knowledge, enables us to manufacture clean surface finishes which is ideal for anodising or sealing.
Certified Welding
Robotic and manual CMT, TIG, MIG and Laser welding to BS EN ISO 9606-2 and ISO 3834-2
Our customers look to our expertise when it comes to the welding of 6082-T6 to maximise structural integrity whilst minimising distortion. Based on the design requirement we have the capability to use the full range of welding methods; this includes CMT, TIG and Laser welding. These can be carried out manually by experienced fabricators or robotically through our welding robots. All of our welders are qualified to BS EN ISO 9606-2 for the fusion welding of Aluminium Alloys including 6082-T6, and the company is accredited to BS EN ISO 3834-2 for safety critical welding standards. Furthermore, where there is a customer requirement, the welding procedure can also be accredited.
Assembly & Integration
Dedicated EV team handling complex assemblies, sub-assemblies, and hardware fitting
Alongside the manufacture of the enclosure itself, we also offer an assembly service. Within this, we can assemble, pack and kit to your requirements.
Leak & Pressure Testing
IP-rated testing, including sealed EV battery enclosures for harsh environments
As 6082-T6 is used for a wide range of enclosures, we can carry out both leak and pressure testing. This testing certifies the enclosures for the full range of IP ratings, ensuring they are fit for their function and working environments. A practical example of this is where we undertake leak testing for Automotive EV Battery Enclosures where the units cannot permit water penetration. Our expertise in this area enables us to machine the units correctly for sealing surfaces, then we are able to prove them out using our certifying testing rigs.
Surface Finishing
Anodising, powder coating, bead blasting, polishing and more via trusted finishing partners
Under our end-to-end management we are able to provide the full range of metal and paint-based finishes. This includes Type II and Type III anodising (clear, black, colours), powder coating, bead blasting and polishing.
Quality & Traceability
Full PPAP (up to Level 5), FAIRs, dimensional reports, and material traceability
We operate ISO 9001:2015-based quality processes and offer a fully traceable service for our customers’ products. We are experienced in providing the full documentation for both industry and customer-specific requirements. As an indication of this, we successfully work within the Automotive, Defence (Marine & Land), Construction, EV and Power Generation sectors. Our experienced Quality Managers are supported by inspectors who are fully trained in the use of Shadow Graphs, FARO Arms and programmable CMMs. This enables us to provide PPAP documentation up to Level 5, dimension reports and FAIRs.
If you have an EV battery enclosure you require manufacturing, get in touch and our engineering experts will be happy to assist you.
