Enclosures and housings
E-Bike Battery Enclosure – Sheet Metal Flat Patterns
- Bounding box
- 1320.0 × 259.0 × 2.0 mm
- Engine
- Precision B-rep
- Parameters
- 15
- Published
- November 2, 2026
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The prompt
Design a sheet metal enclosure for an e-bike battery with a side-loading access layout. Material: 2mm steel sheet. Outer dimensions: length 420mm, total width 80mm. Variable height: 80mm dropping to 50mm (polygon shape for a bicycle triangle). The main body consists of the back wall, top, bottom, and two end-caps welded together. The entire drive-side (right) profile must be a removable/hinged side cover lid. To secure the side lid, the main body must feature integrated 15mm internal bending flanges with M4 weld nuts. The side cover should attach flush to these flanges using 6 to 8 countersunk M4 screws to prevent leg interference while pedaling. Output a 2D flat pattern DXF file for laser cutting.
Parameters
| Name | Value | Range |
|---|---|---|
| Enclosure Length | 420 mm | 300 – 600 |
| Enclosure Width | 80 mm | 50 – 150 |
| Height (tall end) | 80 mm | 50 – 150 |
| Height (short end) | 50 mm | 30 – 100 |
| Sheet Thickness | 2 mm | 1 – 4 |
| Bend Inner Radius | 2 mm | 1 – 6 |
| Bend K-Factor | 0.42 | 0.3 – 0.5 |
| Internal Flange Width | 15 mm | 10 – 25 |
| Side-Lid Screw Count | 8 | 6 – 10 |
| M4 Clearance Hole Dia | 4.5 mm | 4 – 5 |
| M4 Countersink Dia | 8.5 mm | 7.5 – 10 |
| M4 Weld-Nut Pilot Dia | 4.3 mm | 4 – 5 |
| Bend Relief Width | 2.5 mm | 1.5 – 4 |
| Bend Relief Depth | 2.5 mm | 1.5 – 4 |
| Pattern Layout Gap | 30 mm | 10 – 60 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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