Protect your power systems with precision-engineered custom battery enclosures from Hill Plastics. Serving OEM manufacturers, electronics, energy, and industrial sectors across the United States since 1977, our thermoformed and fabricated plastic enclosures deliver exact dimensional accuracy, durable material performance, and cost-effective production from prototype to high-volume runs.
From design through production, we offer a full range of plastic manufacturing services tailored to custom battery enclosure requirements.
We heat and form plastic sheets over precision molds to create durable, dimensionally accurate battery enclosure housings. Using eight thermoforming machines up to 5'x9', we support both short-run and high-volume enclosure production with quick lead times.
Our fabrication department delivers fully finished battery enclosures using CNC routing, precision drilling, heat bending, bonding, and edge finishing — producing assembly-ready parts that meet exact drawing specifications in any quantity.
Two 5'x10' CNC trimming centers perform primary and secondary trim operations on enclosure parts, ensuring clean edges, precise cutouts, fastener preparation, and repeatable production quality for every battery housing we produce.
We design and manufacture low-cost wood and polyurethane prototype tooling as well as aluminum production molds — giving battery enclosure customers a fast, affordable path from concept approval to full production.
Using low-cost tooling and SolidWorks-guided CNC machining, we produce accurate battery enclosure prototypes in weeks, allowing customers to validate fit, form, and function before committing to production tooling.
Our sales and engineering team evaluates your battery enclosure requirements — considering impact resistance, chemical exposure, UV stability, and thermal properties — to recommend the ideal material and tooling design for your application.
Our engineering team — led by Brad and Cody Hill — reviews your battery enclosure specifications, application environment, and performance requirements. We assess dimensional constraints, mounting needs, and any electrical or thermal considerations to establish a clear project scope.
See how OEM manufacturers and industrial customers rely on Hill Plastics for precision battery enclosures.
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
For over four decades, Hill Plastics has been the trusted manufacturing partner for engineers and procurement teams who need precision enclosures delivered on time and on budget.
Founded in 1977, our staff carries a minimum of 20 years of industry experience — giving your battery enclosure project seasoned engineering judgment at every stage.
From SolidWorks design and prototype tooling to CNC trimming and final fulfillment, every step of your enclosure's production happens under one roof in Lewisville, Texas.
Low-cost wood and polyurethane prototype tooling lets U.S.-based OEMs validate designs quickly before investing in aluminum production molds — reducing risk and time to market.
Our 4'x7' rotary thermoformer, eight forming machines, and 20,000+ sq. ft. facility can scale battery enclosure production from short prototype runs to thousands of parts nationwide.
Our engineering and sales experts guide your project from concept to completed enclosure.
Sales & Engineering Team
Brad Hill brings deep expertise in plastic thermoforming design and materials engineering to every customer project. As a key member of Hill Plastics' sales and engineering team, Brad specializes in helping clients navigate the complexities of material selection—evaluating cost, impact requirements, durability, tensile strength, chemical resistance, and environmental factors to identify the optimal PS or HIPS grade for each unique application. He works closely with customers from initial concept through prototype approval, offering guidance on tooling design, process optimization, and production planning. Brad's hands-on approach ensures that every thermoformed component is engineered for performance, manufacturability, and cost-effectiveness. His commitment to collaborative problem-solving and technical precision has made him a trusted advisor to OEM manufacturers, aerospace clients, and medical device companies nationwide. With a focus on delivering turnkey solutions that meet exact specifications, Brad exemplifies Hill Plastics' dedication to quality, innovation, and customer success.
Sales & Engineering Team
Cody Hill is a skilled plastics engineer and sales professional with a passion for transforming customer ideas into precision-manufactured reality. As part of Hill Plastics' dedicated sales and engineering team, Cody provides expert consultation on product design, material selection, and tooling strategy for custom thermoforming projects. He leverages advanced CAD tools like SolidWorks to collaborate with clients on design refinements, ensuring optimal part geometry, wall thickness distribution, and draft angles for successful vacuum forming. Cody's technical knowledge spans the full spectrum of PS and HIPS materials, enabling him to recommend the best plastic grade based on application-specific demands such as impact resistance, rigidity, clarity, and cost. From rapid prototyping using low-cost tooling to scaling up for high-volume production runs, Cody guides customers through every phase of the manufacturing process with transparency and attention to detail. His proactive communication style and commitment to delivering on-time, on-budget results have earned him the trust of clients across aerospace, telecommunications, industrial equipment, and medical device sectors.
Hill Plastics works with ABS, High-Temperature ABS, HDPE, PETG, UV-Resistant ASA/ABS, Polystyrene, KYDEX, and decorative foil-laminated materials. Material selection is based on your enclosure's requirements for impact resistance, thermal performance, chemical exposure, UV stability, and tensile strength — our engineering team guides you to the best fit.
Speak with our engineering team for expert guidance and a no-obligation project review.
Hill Plastics ships custom battery enclosures and fabricated plastic parts to customers across the entire United States.
Nationwide USA
Service Area
Lewisville, TX
Manufacturing Location
Mon–Fri, 7AM–4:30PM
Business Hours
Contact our Lewisville, Texas facility today to discuss your custom battery enclosure requirements.
Serving OEM manufacturers and industrial clients since 1977.
Engineering and CNC operations powered by industry-standard SolidWorks software.
Large-scale manufacturing infrastructure supporting prototype to high-volume production.
Tell us about your enclosure requirements — dimensions, material, volume, and application — and our engineering team will respond with expert guidance and competitive pricing. We support projects from initial design through production fulfillment.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.