Today we're discussing one of our clients, Xerotech, an award-winning battery technology company dedicated to addressing one of the most significant challenges of our generation: industrial electrification and the rapid transition to sustainable energy.
As an innovative company specializing in advanced battery technology, Xerotech has made numerous breakthroughs in the electrification of off-highway vehicles (OHVs), helping traditionally high-emission industrial equipment transition to zero-carbon operation. https://www.swellderplastics.com/vacuum-forming-battery-cover/vacuum-forming-cover-manufacturer-battery.html
1. Breakthrough in High-Temperature Battery Technology
Hibernium™ Battery Platform: Xerotech has developed a battery system designed for extreme environments, addressing the thermal management challenges of off-highway machinery (such as excavators, forklifts, and agricultural machinery) operating under high-temperature, high-load conditions. Its patented technology extends the battery's operating temperature range to -40°C to +60°C, significantly improving equipment reliability and lifespan in harsh environments.
Passive Thermal Protection: Through innovative materials, Xerotech achieves thermal runaway protection without the need for external cooling, reducing system complexity and adapting to the compact footprint of construction machinery.
2. Modularity and Flexible Adaptability
Scalable Architecture: Xerotech's battery systems support diverse power requirements, from small warehouse equipment to large mining trucks. The modular design allows customers to flexibly adjust capacity and voltage based on equipment type (such as AGVs, cranes, or tractors).
Quick Integration: Providing standardized interfaces shortens OEMs' electrification transformation cycles and reduces R&D costs.
3. Extended Range and Fast Charging
High Energy Density: Its batteries boast superior energy density compared to traditional industrial batteries, enabling extended operation with minimal charging interruptions (for example, providing 8-10 hours of continuous operation for a forklift).
Fast Charging Compatibility: Supports high-power charging (e.g., rates above 1C), meeting the intermittent operation requirements of construction machinery and improving equipment utilization.
Through these innovations, Xerotech has significantly lowered the technical and economic barriers to industrial electrification, accelerating the decarbonization of high-emission sectors such as construction, agriculture, and mining. Its technology not only improves performance but also reshapes the sustainability of industrial energy use from a full lifecycle perspective.
As Xerotech's battery housing supplier, we use advanced thermoforming technology to customize high-performance, flame-retardant V0-grade plastic housings to meet the stringent requirements of industrial batteries used in off-highway machinery (such as excavators, forklifts, and agricultural equipment). The following are the key advantages of blister molding technology in Xerotech's battery housing applications:
1. Lightweight Design, Improved Battery Efficiency
Vacuum forming plastic housings are 30%-50% lighter than traditional metal housings, reducing overall weight and increasing the range of electric construction machinery. Made of PC/ABS or flame-retardant PP materials, they optimize energy efficiency while ensuring strength.
2. High-Grade Flame Retardancy, Ensures Battery Safety
The housings meet the FR V0 flame retardancy standard, effectively suppressing flame spread in the event of thermal runaway. Combined with Xerotech's advanced thermal management system, they provide dual protection, suitable for high-temperature, high-load industrial environments.
3. Impact-Resistant, Dustproof, and Waterproof, Suitable for Harsh Operating Conditions
Thermoforming housings feature integrated reinforcing ribs and snap-fit structures for enhanced impact resistance, ensuring they can withstand the vibration and impact of construction machinery. Through ultrasonic welding or sealant application, it achieves IP67 protection, resisting dust and water, making it suitable for extreme environments such as mines and construction.
4. Fast Production and Reduced Costs
The development cycle for thermoforming molds is short, and the cost is only 30%-50% of that of injection molds, making it suitable for rapid iteration of Xerotech's diverse battery models. Its high production efficiency makes it suitable for medium to large-volume production, reducing unit costs and facilitating the large-scale application of electric machinery.
5. Environmentally Sustainable, In line with carbon neutrality goals
Recyclable flame-retardant plastics are used to reduce material waste. The blister process has a scrap rate of less than 5%, making it more environmentally friendly than traditional processing methods and supporting Xerotech's sustainability strategy.
6. Highly Customizable to Meet Complex Needs
The thermoforming process allows for flexible adjustment of the housing shape, thickness, and functional structures (such as heat dissipation holes and cable ducts) to precisely match different battery models. It supports small-batch trial production, accelerating product verification and market launch.
Why Choose Vacuum forming?
Lighter: Reduces equipment weight and improves energy efficiency.
Safer: V0 flame retardant, preventing fire risks.
More durable: Impact-resistant and adaptable to harsh environments.
More economical: Low mold costs and high mass production efficiency.
More environmentally friendly: Recyclable materials, reducing carbon footprint.
As a partner of Xerotech, we support the application of their battery technology in construction machinery through high-performance thermoforming, jointly driving the transition to industrial electrification. Although Xerotech has withdrawn from the market, we welcome new partners seeking vacuum forming solutions. For custom flame-retardant V0-rated battery requirements, please contact us for solutions.