Global ​Roll-formed Battery Enclosure Market Strategic Research Report

Scope of the Report

The global ​Roll-formed Battery Enclosure market size is predicted to grow from US$ 307 million in 2025 to US$ 1,571 million in 2032; it is expected to grow at a CAGR of 26.6% from 2026 to 2032.

Battery Enclosure, also known as "battery tray", "battery box Enclosure", etc. Its design mainly considers the functions of protecting the battery pack, providing support and connection, heat dissipation, and convenient installation and maintenance. Battery Enclosure is usually used to wrap the battery to ensure the safe operation of the battery pack and provide appropriate environmental and structural support.

Roll-formed Battery Enclosure is a metal shell structure manufactured by continuous roll forming process, specially designed for new energy vehicle power battery system. It uses high-strength steel or aluminum alloy strip, and is formed by multi-pass roller progressive bending to form a box component with a specific cross-sectional shape. It has the characteristics of lightweight, high strength and modular integration, and is the core carrier of battery pack structural safety and thermal management.

With the increasingly severe global climate problems and the continuous improvement of environmental awareness, electric vehicles, as a low-carbon and environmentally friendly mode of transportation, are gradually becoming the focus of attention of countries around the world. At present, electric vehicle technology is constantly improving, and problems such as cruising range and charging facilities have been gradually solved, and market demand is gradually growing. Driven by policy support and technological innovation, the electric vehicle industry has become an important development direction of the global automotive industry. Governments of various countries have introduced encouraging policies to increase the research and development and promotion of electric vehicles.

Among them, the battery pack is the core component of electric vehicles. It provides power for electric vehicles and accounts for 30% to 40% of the cost of the whole vehicle. The battery pack mainly includes enclosure mechanical structural parts, battery modules, and battery management systems. The enclosure mechanical structural parts include upper covers and enclosures. Battery Enclosure is an important part of the battery pack, which has an important impact on the performance, safety and life of the battery pack. The enclosure under the battery pack of electric vehicles refers to the shell installed at the bottom of the battery pack, which is used to support, fix and protect the battery modules, battery management systems and other components inside the battery pack.

The main electric vehicle power battery enclosures on the market include aluminum alloy enclosures, sheet metal stamping enclosures, and steel roll-formed battery enclosures. Enclosures are mainly composed of aluminum alloy profile frames and aluminum alloy profile bottom plates, and the frames and bottom plates are aluminum alloy extruded profiles. Sheet metal stamping enclosures are stamped and formed by sheet metal in one piece, with crossbeams and longitudinal beams welded in a crisscross pattern in the middle. Sheet metal forming parts play a sealing role, and crossbeams and longitudinal beams play a structural support role. Roll-formed battery enclosures are similar to sheet metal stamping enclosures, with steel roll-formed profile frames, steel panels on the bottom, and crossbeams and longitudinal beams welded in the middle.

In terms of structural strength, steel roll-formed battery enclosures have the highest strength, followed by aluminum alloy enclosures, and sheet metal stamping enclosures have the lowest strength. Therefore, sheet metal stamping enclosures are used for battery packs that are lighter in weight and smaller in size. In terms of manufacturing cost, aluminum alloy enclosure has the highest cost due to the high cost of aluminum materials. The cost of steel rolled battery enclosure and sheet metal stamping enclosure is similar, but sheet metal stamping enclosure requires molds of different specifications for different models, and the mold cost is high. Steel rolled battery enclosure only needs to open the mold once, and can be transformed into enclosures of different models and sizes by adjusting the length and width of the rolled profile.

According to our data, the global shipment of Roll-formed Battery Enclosure will be about 1.3 million units in 2024, and will reach 9 million units in 2031, with a compound annual growth rate of more than 30% during the test period. China occupies the largest downstream market, with a market share of more than 75% in 2024. Major global manufacturers include Suzhou Yichuangte Intelligent Manufacturing, Novelis, Lucky Harvest, Magna International, Changzhou Hugestone New Energy Technologies, Liuzhou Aode Yongxing Automotive Parts Technology, Forvia, Voestalpine Metal Forming GmbH, Suzhou Prysler Advanced Forming Technology, Ningbo Huaxiang Electronic, XD Thermal, Lingyun Industrial Corporation, Nabaichuan Holding, etc. In 2024, the global TOP5 market share will exceed 60%. In terms of product types, the European and American regions mainly use steel and aluminum Roll-formed Battery Enclosure products, among which Novelis products are the most famous for aluminum Roll-formed Battery Enclosure, while China basically uses high-strength steel and ultra-strong steel Roll-formed Battery Enclosure.

As an important component of electric vehicle power batteries, the unique process and design of Roll-formed Battery Enclosure bring many significant advantages. First of all, compared with traditional aluminum alloy Enclosure, the cost of parts of Roll-formed Battery Enclosure can be reduced by more than 30%. Through the thin-wall design of high-strength steel materials, it not only maintains lightweight but also enhances structural strength. Secondly, Roll-formed Battery Enclosure uses ultra-high-strength steel materials (such as 980DP, 1180DP), and its tensile strength is as high as 1500MPa or more, which can more effectively protect the battery system from external impact. In addition, Roll-formed technology adopts a multi-roller structure, and its production efficiency is more than 10% higher than that of traditional stamping, which is suitable for mass production. Moreover, Roll-formed is suitable for processing parts with complex shapes, which provides more possibilities for the innovative design of battery enclosure. In general, Roll-formed Battery Enclosure has broad application prospects in the mid- and low-end vehicle market due to its advantages of low cost, high strength, high production efficiency, light weight and environmental protection. We believe that Roll-formed Battery Enclosure will soon become a key solution that various car companies and battery pack manufacturers will compete to research and develop.

This report presents a comprehensive overview of the global ​Roll-formed Battery Enclosure market, covering market size and forecast, segmentation by product type and application, competitive landscape, leading players and regional and country-level outlook.

Segment by Type

• Aluminum Alloy Material
• Steel Material

Segment by Application

• Passenger Vehicle
• Commercial Vehicle

Who Can Use This Report?

This report is written for decision-makers who need a clear, data-backed view of the global ​Roll-formed Battery Enclosure market:

• Manufacturers, suppliers and solution providers benchmarking their position and planning product, capacity and go-to-market strategy
• Distributors, channel partners and end users in Passenger Vehicle, Commercial Vehicle evaluating demand and sourcing options
• Investors, financial analysts and consultants assessing growth opportunities, competitive dynamics and M&A potential
• Government agencies, industry associations and research institutions tracking industry developments and policy impact