Battery Box Calculator

PVC is lighter, cheaper, and faster to fabricate (solvent-welded corners). Ideal for indoor battery containment, drip trays, and general-purpose boxes. Available in 4.5mm grey as standard.

HDPE is tougher, more chemically resistant, and handles higher temperatures. Corners are extrusion-welded (a stronger but slower process using filler rod). Choose HDPE for acid battery environments, outdoor use, or where impact resistance matters. Available in 6mm as standard.

The lid is a separate flat sheet with bent lip edges on all four sides. The lips fold down over the box walls to locate the lid in place — it's a removable friction fit, not hinged. The lip overhang (default 20mm) determines how far down the lid sits on the box. Lid corners overlap at the folds and are left unjoined.

Battery boxes are made to order. Typical lead time is 5–7 business days for PVC and 7–10 business days for HDPE (extrusion welding requires more setup). Rush orders may be available — mention it in your quote request.

Every box is cut and bent to your exact dimensions. The calculator handles any size that fits within a 2440×1220mm sheet (accounting for wall height). For very large boxes or non-standard configurations, contact us to discuss options.

Key pricing factors: (1) material — HDPE costs more per sheet and takes longer to weld; (2) size — larger blanks use more sheet material; (3) quantity — more boxes nest more efficiently on sheets; (4) wall height — taller walls increase blank size; (5) lid — adds a second blank per box. HDPE also includes a filler rod consumable cost per welded joint ($2.50/joint).

HDPE cannot be solvent-welded like PVC — it requires extrusion welding, where a filler rod is melted into the joint using a specialised welding gun. This takes about 5 minutes per joint (vs 2 minutes for PVC solvent welding), uses a consumable filler rod, and requires a higher-skilled operator. The result is a stronger, fully fused joint that's essential for chemical containment and high-stress applications.