Sustainable Battery Housings Made from Recycled Plastic Instead of Aluminum
How NAEXT improved insulation properties by switching to 100% recycled plastic while simultaneously reducing weight, costs, and CO₂ emissions.
About NAEXT
NAEXT is a German manufacturer of sustainable energy storage systems. The company uses so-called second-life batteries from electric vehicles, refurbishes them technically, and reuses them in stationary storage systems. The goal is to extend the lifespan of existing resources and actively contribute to the energy transition.
Application
Battery housings / protective covers
Industry
Electronics
Material
100% recycled ABS
Post-processing
CNC milling
Watch the case study video to learn how NAEXT and formary implemented a more sustainable and efficient housing solution.
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This project demonstrates the potential of switching materials from aluminum to plastic: A heavy, energy-intensive aluminum component was replaced by a fully recycled plastic solution—with advantages in insulation properties, weight, cost, handling, and sustainability. At the same time, the project was successfully transitioned into series production despite very tight timelines.
Project Overview
- Objective: Develop a sustainable, lighter, and more cost-efficient alternative to aluminum battery housings with improved insulation and material properties
- Challenge: High requirements for safety, dust and environmental protection, and material performance, combined with a very short time-to-market
- Solution: Development of a two-part thermoformed solution made from 100% recycled ABS as a functional alternative to aluminum
- Result: Significantly reduced weight and material costs, improved insulation properties, and a quickly available, production-ready solution
The Problem
Sustainable Energy Storage with Inefficient Components
NAEXT follows a consistently sustainable approach: batteries from electric vehicles are given a second life in stationary energy storage systems. However, a key inconsistency became apparent during the project: the protective covers used were made of primary aluminum.
These components are heavy, expensive, and energy-intensive to produce—contradicting the overall sustainability goals of the system.
The Challenge
Replacing a Heavy, Cost- and Energy-Intensive Aluminum Component Under Tight Deadlines
NAEXT set out to align the protective covers of their energy storage systems with their sustainability standards by replacing the existing aluminum housing with a more efficient and resource-saving alternative. The requirements for the new solution were clearly defined and technically demanding:
- Protection against contact with live components
- Dust and environmental protection for safe operation
- High insulation performance
- Low weight for easier handling
- Use of sustainable (recycled) materials
- Very short development and delivery timelines
The Solution
Design and Manufacturing Optimization via Thermoforming and Combination Tooling
Together with NAEXT, formary developed a completely new housing solution, consistently replacing aluminum with recycled plastic. The design was optimized so that:
✓ The lid and base could be produced using a single combination tool
✓ Only one tool is required
This reduced both production time and investment costs. At the same time, a second variant was implemented at short notice, also made from 100% recycled ABS. To meet the tight schedule, a regional production partner with immediate capacity was integrated via the formary supplier network, enabling development and manufacturing without delays.
The Advantage
Short Distances for Maximum Speed and Coordination
By selecting a production partner located near NAEXT’s site, prototypes could be reviewed locally, picked up in person, and directly integrated into the application. Changes and iterations were implemented without delay.
The result: maximum implementation speed combined with high quality and close coordination among all parties involved.
Material Change
A Key Lever for Cost, Performance, and Sustainability
Switching from aluminum to recycled plastic delivered multiple benefits:
✓ Significantly lower weight
✓ Improved technical properties
✓ Easier handling in daily use
✓ Reduced manufacturing energy
✓ Lower costs
“It was very important to us to have a supplier who would support us right from the start of this development, and that’s exactly what we found in formary.”
— Henning Behn, NAEXT
The Result
Sustainable, Scalable, and Successfully Transferred to Series Production
The jointly developed housing components are now an integral part of NAEXT’s energy storage solutions. The project created a strong foundation for scalable future development.
Key success factors included:
- Fast implementation despite tight timelines
- Transferability to additional variants
- Combination of design expertise, supplier network, and manufacturing competence
Mr. Behn adds:
“The combination of technical expertise, regional network, and fast responsiveness made this project so straightforward to implement.”
FAQ – Frequently Asked Questions About Battery Housings & Material Substitution
Plastic—especially recycled material—can be produced much more energy-efficiently and allows for lighter components.
Further Reading
What is Recyclate? Plastic Recycling in the Spotlight
Blog
We’ll explain what the term means and how recycled materials differ from virgin materials.
Material Guide for Thermoformed Parts
Whitepaper
Find out what materials are available for plastic deep-drawing and what you should bear in mind when choosing a material.
Would you like to rethink an existing component?
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