Aluminum 6061 plates for EV battery trays

At the heart of every electric vehicle is the battery pack—its most expensive and critical component. Protecting this vital component requires a lightweight, extremely robust, thermally efficient, and shock-resistant casing. Aluminum 6061 plates is the material of choice for electric vehicle battery trays.

5 Key Benefits of Aluminum 6061 Plates for EV Battery trays

• High Strength for Crash Protection and Structural Integrity
• Superior Machinability for Complex Designs
• Excellent Thermal Conductivity
• Dimensional Stability and Flatness
• Corrosion Resistance and EMI Shielding

Common Applications in EV Battery Pack Design

6061 plates are used in various forms throughout the battery pack architecture:

Base Trays : The main structural plate that holds the weight of the modules. Usually a thicker gauge (3mm to 8mm) to provide rigidity .

Internal Cross Members and Bracing: Extruded or machined from plate to separate cell modules and add crush resistance .

Cold Plates: Machined from plate to create channels for liquid coolant to flow directly beneath the cells.

Lid or Cover: Thinner gauge plates (1mm to 2mm) that seal the top of the pack while providing protection from above .

Busbar Supports: Non-conductive coated 6061 can be used as structural support for high-voltage busbars .

6061-T6 vs. 5052-H32 vs. 7075: Which is Right for Battery Trays?

6061-T6 vs. 5052-H32: While 5052 has better corrosion resistance and formability, 6061 is stronger and machines better. For a machined structural tray that requires tapped holes and flat sealing surfaces, 6061 is the standard. 5052 is better suited for thin, bent covers .

6061-T6 vs. 7075-T6: 7075 is an aerospace alloy with extremely high strength. However, it is very expensive and difficult to weld. For cost-effective automotive production, 6061 provides the best balance of price, weldability, and strength .

Ready to secure high-quality 6061 plates for your next EV project?

Contact us today for a quote, material certifications, or to discuss custom sizes for your battery tray manufacturing line.