Roll-formed Battery Enclosure Market Report: the global market is projected to reach US$ 1574 million

QY Research Inc. (Global Market Report Research Publisher) announces the release of 2025 latest report "​Roll-formed Battery Enclosure- Global Market Share and Ranking, Overall Sales and Demand Forecast 2026-2032". Based on current situation and impact historical analysis (2020-2024) and forecast calculations (2026-2032), this report provides a comprehensive analysis of the global ​Roll-formed Battery Enclosure market, including market size, share, demand, industry development status, and forecasts for the next few years.

The global market for ​Roll-formed Battery Enclosure was estimated to be worth US$ 298 million in 2025 and is projected to reach US$ 1574 million, growing at a CAGR of 27.2% from 2026 to 2032.

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What Is a Roll-Formed Battery Enclosure?
A battery enclosure-also known as a battery tray or battery box-is a protective shell that houses a battery pack. Its design focuses on protecting the battery modules, providing structural support and electrical connections, enabling heat dissipation, and allowing convenient installation and maintenance.

A roll-formed battery enclosure is a metal structure manufactured using a continuous roll forming process, specifically designed for electric vehicle (EV) power battery systems. It starts with high-strength steel or aluminum alloy strips that are progressively bent through multiple roller stations to create box components with precise cross-sectional shapes. Key characteristics include lightweight construction, high strength, and modular integration, making it a core component for battery pack structural safety and thermal management.

Industry Context: The Rise of Electric Vehicles
As global climate concerns intensify and environmental awareness rises, electric vehicles have become a strategic focus for many countries. EV technology continues to improve, with range and charging infrastructure challenges gradually being resolved. Government policies and incentives worldwide are accelerating EV research, production, and adoption.

The battery pack is the most critical component of an EV, providing all propulsion power and accounting for 30-40% of total vehicle cost. A battery pack consists of three main parts: enclosure mechanical structural components (upper cover and lower enclosure), battery modules, and a battery management system. The enclosure-particularly the lower part mounted at the vehicle underside-supports, fixes, and protects the internal modules and electronics.

Comparison of Enclosure Types
Three main types of EV power battery enclosures exist today: aluminum alloy enclosures, sheet metal stamping enclosures, and steel roll-formed enclosures.

Aluminum alloy enclosures use extruded profiles for frames and bottom plates. Sheet metal stamping enclosures are stamped as single pieces with crossbeams and longitudinal beams welded inside; the stamped part provides sealing while the beams provide structural support. Roll-formed enclosures are similar in design to stamped ones but use steel roll-formed profiles for frames, steel panels for the bottom, and welded crossbeams and longitudinal beams.

In terms of structural strength, steel roll-formed enclosures are strongest, followed by aluminum alloy, then sheet metal stamping. Thus, stamped enclosures are used for lighter, smaller battery packs. In manufacturing cost, aluminum enclosures are most expensive due to high material costs. Steel roll-formed and stamped enclosures have similar material costs, but stamping requires different molds for each vehicle model-resulting in high tooling expenses. Roll-formed enclosures require only one mold, with length and width adjustments of the roll-formed profile enabling different sizes and models.

Market Size and Growth Outlook
Global shipments of roll-formed battery enclosures reached approximately 1.3 million units in 2024. By 2031, shipments are projected to reach 9 million units, representing a compound annual growth rate (CAGR) of over 30% during the forecast period. The market value is projected to reach USD 1.26 billion by 2031, at a CAGR of 25.9%.

Regional and Competitive Landscape
China dominates the downstream market, accounting for more than 75% of global demand 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, and Nabaichuan Holding. In 2024, the global top five players held over 69.0% of revenue.

In terms of product types, Europe and North America use both steel and aluminum roll-formed enclosures, with Novelis being most well-known for aluminum products. China predominantly uses high-strength steel and ultra-high-strength steel roll-formed enclosures.

Key Advantages of Roll-Formed Battery Enclosures
Roll-formed battery enclosures offer several compelling benefits. First, compared to traditional aluminum alloy enclosures, part costs can be reduced by more than 30%. The thin-wall design using high-strength steel maintains lightweight construction while enhancing structural strength.

Second, ultra-high-strength steel materials (such as 980DP and 1180DP) achieve tensile strength up to 1500 MPa or higher, more effectively protecting the battery system from external impacts.

Third, the roll-forming process uses a multi-roller structure that is more than 10% more productive than traditional stamping, making it well suited for mass production.

Fourth, roll forming is ideal for processing complex-shaped parts, enabling innovative enclosure designs. Additional benefits include lightweighting and environmental friendliness due to efficient material use and recyclability of steel.

Segmentation by Product Type and Application
By material, steel roll-formed enclosures are the largest segment, holding a 69.2% market share. Aluminum enclosures account for the remainder.

By application, passenger vehicles dominate, representing 86.2% of the market. Commercial vehicles and other EV segments make up the balance.

Outlook
Roll-formed battery enclosures have broad application prospects, particularly in the mid-range and entry-level EV market segments. Their combination of low cost, high strength, high production efficiency, lightweight construction, and environmental benefits makes them increasingly attractive. As EV adoption accelerates globally, roll-formed battery enclosures are expected to become a key solution that automakers and battery pack manufacturers actively research, develop, and deploy. With a projected CAGR of over 25%, this market represents one of the fastest-growing segments in EV structural components.

The report provides a detailed analysis of the market size, growth potential, and key trends for each segment. Through detailed analysis, industry players can identify profit opportunities, develop strategies for specific customer segments, and allocate resources effectively.

The ​Roll-formed Battery Enclosure market is segmented as below:
By Company
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

Segment by Type
Aluminum Alloy Material
Steel Material

Segment by Application
Passenger Vehicle
Commercial Vehicle

Each chapter of the report provides detailed information for readers to further understand the ​Roll-formed Battery Enclosure market:

Chapter 1: Introduces the report scope of the ​Roll-formed Battery Enclosure report, global total market size (valve, volume and price). This chapter also provides the market dynamics, latest developments of the market, the driving factors and restrictive factors of the market, the challenges and risks faced by manufacturers in the industry, and the analysis of relevant policies in the industry. (2021-2032)
Chapter 2: Detailed analysis of ​Roll-formed Battery Enclosure manufacturers competitive landscape, price, sales and revenue market share, latest development plan, merger, and acquisition information, etc. (2021-2026)
Chapter 3: Provides the analysis of various ​Roll-formed Battery Enclosure market segments by Type, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different market segments. (2021-2032)
Chapter 4: Provides the analysis of various market segments by Application, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different downstream markets.(2021-2032)
Chapter 5: Sales, revenue of ​Roll-formed Battery Enclosure in regional level. It provides a quantitative analysis of the market size and development potential of each region and introduces the market development, future development prospects, market space, and market size of each country in the world..(2021-2032)
Chapter 6: Sales, revenue of ​Roll-formed Battery Enclosure in country level. It provides sigmate data by Type, and by Application for each country/region.(2021-2032)
Chapter 7: Provides profiles of key players, introducing the basic situation of the main companies in the market in detail, including product sales, revenue, price, gross margin, product introduction, recent development, etc. (2021-2026)
Chapter 8: Analysis of industrial chain, including the upstream and downstream of the industry.
Chapter 9: Conclusion.

Benefits of purchasing QYResearch report:

Competitive Analysis: QYResearch provides in-depth ​Roll-formed Battery Enclosure competitive analysis, including information on key company profiles, new entrants, acquisitions, mergers, large market shear, opportunities, and challenges. These analyses provide clients with a comprehensive understanding of market conditions and competitive dynamics, enabling them to develop effective market strategies and maintain their competitive edge.

Industry Analysis: QYResearch provides ​Roll-formed Battery Enclosure comprehensive industry data and trend analysis, including raw material analysis, market application analysis, product type analysis, market demand analysis, market supply analysis, downstream market analysis, and supply chain analysis.

and trend analysis. These analyses help clients understand the direction of industry development and make informed business decisions.

Market Size: QYResearch provides ​Roll-formed Battery Enclosure market size analysis, including capacity, production, sales, production value, price, cost, and profit analysis. This data helps clients understand market size and development potential, and is an important reference for business development.

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