Custom Aluminum Battery Trays (Van/Light Truck/Bus) – One-Stop Service: Profile Molding, CNC Deep Processing & Surface Treatment
Custom Aluminum Battery Trays are precision-engineered storage and protection components specifically designed for van, light truck, and bus battery systems. Crafted from high-grade aluminum by Zhonglian Aluminum-an experienced one-stop aluminum solution factory-these trays are tailored to fit diverse battery sizes, installation spaces, and operational requirements of commercial vehicles. Unlike generic battery holders, our custom trays prioritize structural stability, corrosion resistance, and long-term compatibility with vehicle electrical systems, ensuring safe and reliable battery performance even in harsh road conditions (e.g., vibration, temperature fluctuations, moisture).
Products Details
| Parameter | Specification | Applicable Vehicle Type |
|---|---|---|
| Material | Aluminum Alloy (6061, 6082, 5052) | Van, Light Truck, Bus |
| Dimensions (Customizable) | Length: 200-2000mm; Width: 150-1500mm; Height: 50-500mm | All models (e.g., Ford Transit, Toyota Hilux, City Buses) |
| Weight Capacity | 50-500kg (depending on design) | Light Truck (50-200kg), Van (50-150kg), Bus (200-500kg) |
| Surface Treatment | Anodizing (5-20μm), Powder Coating (60-80μm), E-Coating, Passivation | All (based on climate/use case) |
| Tensile Strength | Up to 310 MPa (6082 alloy) | Van, Light Truck, Bus |
| Corrosion Resistance | Salt Spray Test: 500+ hours (no rust) | Coastal/harsh climate regions |
| Thermal Conductivity | 205 W/m·K (aluminum base material) | All (especially EV buses/vehicles) |
| Installation Type | Bolt-on, Weld-on, or Clip-on (customizable) | Van (bolt-on), Light Truck (weld-on/bolt-on), Bus (weld-on) |
| Certification | CE, TUV, SGS, RoHS, ISO 9001, KS | Global markets (EU, U.S., Asia) |
| Lead Time | Prototypes: 5-7 days; Bulk Production: 10-15 days | All order types |
| MOQ | 50 units (small batch); No MOQ for bulk orders | Aftermarket (small batch); Manufacturers (bulk) |
| Warranty | 5-year warranty against material defects | All customers |
Why Choose Our Aluminum Battery Trays：Stand out with customer-centric design, industrial-grade quality, solving vehicle makers', fleet managers' & aftermarket buyers' key pain points
Made from premium aluminum alloys (e.g., 6061, 6082), the trays weigh 30-40% less than steel alternatives-reducing vehicle curb weight to improve fuel efficiency-while boasting a tensile strength of up to 310 MPa to withstand heavy battery loads (supports 50-500kg, depending on custom specs).
Superior Corrosion Resistance:
Undergoes professional surface treatment to resist rust, oxidation, and chemical damage from battery electrolytes or road salts, extending the tray's service life to 8-12 years (2x longer than untreated aluminum).
Integrated reinforcement ribs and anti-slip padding (optional) minimize battery movement during vehicle operation, preventing internal battery damage, loose connections, and short circuits-critical for fleet reliability.
Precision Fit for All Vehicle Types:
Fully customizable to match the exact dimensions of van, light truck, and bus battery compartments, eliminating the need for modification during installation.
Aluminum's excellent thermal conductivity (205 W/m·K) helps dissipate heat generated by batteries during charging/discharging, preventing overheating and prolonging battery lifespan by 15-20%.
Wide Applications: Perfect for Van, Light Truck & Bus Scenarios
Our Custom Aluminum Battery Trays are engineered to meet the unique demands of commercial vehicle battery systems across industries:
✅ Van Applications: Ideal for delivery vans, utility vans, and camper vans-secures auxiliary batteries for tools, refrigeration units, or off-grid power systems, ensuring uninterrupted workflow for logistics and service businesses.
✅ Light Truck Applications: Designed for pickup trucks, small cargo trucks, and service trucks-supports main or backup batteries for heavy-duty electrical accessories (e.g., winches, lighting, GPS trackers) in construction, agriculture, and emergency services.
✅ Bus Applications: Critical for city buses, school buses, and electric buses (EV buses)-accommodates large-format battery packs (e.g., lithium-ion, lead-acid) with safety features to meet public transportation safety standards, reducing maintenance downtime for fleet operators.
✅ Aftermarket & Custom Vehicle Builds: A top choice for custom vehicle modifiers and specialty fleet owners (e.g., food trucks, mobile workshops) who require tailored battery storage solutions to fit unique vehicle layouts.
Flexible Customization Service: Tailored to Your Exact Needs
As a one-stop aluminum solution factory, Zhonglian Aluminum offers end-to-end customization to turn your requirements into high-quality battery trays-no minimum order quantity (MOQ) for bulk orders, and flexible small-batch customization:
✅ Dimension Customization: Adjust length (200-2000mm), width (150-1500mm), height (50-500mm), and tray depth to fit specific battery models (e.g., Group 31, Group 4D) and vehicle installation spaces.
✅ Design Customization: Add features like handle cutouts for easy installation, drainage holes to prevent water accumulation, cable management slots to organize wiring, or locking mechanisms to prevent theft-all based on your drawings or samples.
✅ Material Customization: Select from aluminum alloys (6061 for general use, 6082 for higher strength, 5052 for enhanced corrosion resistance) to match your performance and budget needs.
✅ Fast Prototyping: With 33+ years of extrusion experience, we deliver custom prototypes in 5-7 business days-accelerating your product development cycle and ensuring design accuracy before mass production.
Precision CNC Deep Processing: Guaranteeing Installation Accuracy
To ensure our Custom Aluminum Battery Trays meet strict fitment standards, we utilize advanced CNC deep processing technology:
- High-Precision Machining: CNC mills, lathes, and routers with ±0.01mm accuracy create holes, slots, and mounting points that align perfectly with vehicle chassis and battery terminals-eliminating installation delays caused by misaligned parts.
- Complex Geometry Handling: Capable of processing intricate tray designs (e.g., curved edges for space-saving, multi-compartment trays for multiple batteries) that generic manufacturing methods cannot achieve.
- Consistency Across Batches: Our 25 extrusion lines and automated CNC systems ensure uniform quality across every tray-critical for fleet buyers who require identical parts for large-scale vehicle maintenance or upgrades.
Professional Surface Treatment: Enhancing Durability & Aesthetics
Surface treatment is a key differentiator of our aluminum battery trays, addressing customer concerns about longevity and environmental resistance:
- Anodizing: Creates a hard, wear-resistant oxide layer (5-20μm thick) that enhances corrosion resistance and allows for custom colors (silver, black, gray) to match vehicle aesthetics-popular for aftermarket and branded vehicle applications.
- Powder Coating: Applies a durable, scratch-resistant polymer coating (60-80μm thick) that withstands UV rays, extreme temperatures (-40°C to 120°C), and chemical exposure-ideal for buses and trucks operating in harsh climates.
- Electrophoretic Coating (E-Coating): Provides uniform coverage even in hard-to-reach areas (e.g., tray corners), offering superior rust protection for trays used in humid or coastal regions.
- Passivation: A chemical treatment that forms a protective film on aluminum surfaces, preventing oxidation during storage and transportation-ensuring trays arrive in perfect condition for installation.
Strict Quality Inspection: Meeting Global Standards
Zhonglian Aluminum prioritizes quality control at every stage of production, ensuring our Custom Aluminum Battery Trays meet or exceed international standards-giving customers confidence in product reliability:
1. Raw Material Inspection: All aluminum ingots are tested for alloy composition, purity, and mechanical properties using 光谱分析 (spectral analysis) and tensile testing machines before extrusion.
2. In-Process Inspection: Extruded aluminum profiles are checked for dimensional accuracy (using 3D scanners) and surface defects (e.g., scratches, dents) every 2 hours during production.
3. Final Product Testing: Finished trays undergo:
- Load-bearing tests (to verify weight capacity)
- Corrosion resistance tests (salt spray testing for 500+ hours)
- Vibration tests (simulating 100,000+ km of road use)
- Installation fitment checks (matching with actual vehicle battery compartments)
4. Certified Quality: Our manufacturing process and products are certified by CE, TUV, SGS, RoHS, ISO 9001, and KS-ensuring compliance with European, North American, and Asian market regulations.
Secure Packaging & On-Time Delivery
We understand that safe and timely delivery is critical for your production schedule-our packaging and logistics solutions address this:
✅ Packaging Options:
- Standard: Plastic film wrapping + foam padding to prevent scratches during transit.
- Custom: Wooden crates or pallets for bulk orders (suitable for sea/air freight) with moisture-proof liners to protect against humidity.
- Branded: Optional custom packaging with your logo for aftermarket or retail distribution.
✅ Global Logistics Partnerships: Collaborate with DHL, FedEx, Maersk, and COSCO to offer flexible shipping options-express delivery (3-5 days) for samples/prototypes, and cost-effective sea freight (20-30 days) for bulk orders. We also provide door-to-door delivery and handle customs clearance documents to simplify your import process.
Global Customer Praise: Trusted by 500+ Clients Worldwide
Our Custom Aluminum Battery Trays have earned positive feedback from customers across 30+ countries, including vehicle manufacturers, fleet operators, and distributors:
User Evaluation
John D.
Executive Chairman
Sarah M.
Executive Chairman
Li T.
Executive Chairman
Zhonglian Aluminum-Your One-Stop Aluminum Solution Factory
Choosing Zhonglian Aluminum means partnering with a reliable, experienced manufacturer that handles every step of your battery tray production-no need to work with multiple suppliers:
✅ Scale & Capacity: 100,000㎡ factory, 25 extrusion lines, and 50,000 tons annual output-capable of fulfilling large orders (10,000+ trays/month) with short lead times (10-15 days for bulk production).
✅ 33+ Years of Extrusion Expertise: Our engineering team has decades of experience in aluminum processing, ensuring optimal design for battery trays (e.g., material selection, structural reinforcement) to meet your performance goals.
✅ One-Stop Service: From aluminum profile opening (custom dies for unique designs) to extrusion, surface treatment, CNC deep processing,and final assembly-we handle all processes in-house, reducing costs and ensuring quality control.
✅ Global Compliance: Certifications including CE, TUV, SGS, RoHS, ISO 9001, and KS ensure our products meet the regulatory requirements of major markets (EU, U.S., Japan, South Korea), making importation seamless.
✅ Customer-Centric Support: English-speaking sales and engineering teams provide 24/7 support-from initial design consultation to post-delivery troubleshooting-ensuring a smooth cooperation experience.
ordering process
We position ourselves as a China-based global aluminum profile solution provider who helps clients develop and design differentiated products, with the aim of helping them win more market share. We have more than 50000 molds in stock. If our aluminum profiles are not suitable for you, you could provide us with your samples or technical drawings, we can extrude them according to your designs. Contact us and get a free quote today!
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