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    Nachhaltige Serienproduktion Wallbox-Gehäuse

    Wallbox Housing with a Focus on Sustainability

    02.10.2024

    In 2024, Fried Kunststofftechnik GmbH commenced the series production of the Wallbox Cubos C44E, marking a significant milestone in the field of e-mobility. This legally compliant charging solution for electric vehicles impresses with its combination of design, technical innovation, and sustainability. Florian Tepper, Head of Charging at CUBOS Technologies GmbH, provides insights into the exciting development of this project.

    Abou the Dual Charger

    The Cubos C44E Wallbox is used in private and semi-public areas, such as hotels, commercial establishments, and company parking lots. It features a power output of 2 × 22 kW and a 5-meter long charging cable, allowing for fast and convenient charging of two vehicles simultaneously. Special attention was paid to sustainability and the modern hexagonal design, which was awarded the Red Dot Award in 2024.

    Plastic as an Alternative to Stainless Steel

    Cubos has produced various charging solutions since 2018. A significant advancement in the development of the Cubos C44E Wallbox compared to previous products is the use of plastic instead of stainless steel. For weight and technology reasons, the dual charging point relies on higher integration of components, leveraging the advantages of plastic technology. This change enables specific shapes, sealing contours, and recesses for easy assembly, while still meeting all industry-specific requirements such as thermal management, impact resistance for public spaces, and flame protection.

    Project Start in 2022

    The decision to collaborate with Fried Kunststofftechnik followed an intensive search for a partner in injection moulding. Tepper explains: “We chose Fried because the company specializes in the structural foam injection moulding process, which was ideal for our project. The possibility of a factory tour and short communication paths also convinced us. ‘Made in Germany’ was also an important aspect for us: we needed a partner in Germany with whom we could quickly implement ideas on an equal footing.”

    Sustainability in Focus

    The main goal of the project was to use sustainable materials. The wallbox is made from a special sustainable plastic material, Bayblend RE from Covestro, produced from recycled plant oils. Covestro newly developed and certified this material combination—a unique assembly to date. The aim was to keep the CO₂ equivalent of the housing as low as possible, contributing to a sustainable product and material circular economy. Additionally, the wallbox is modular, allowing individual components to be easily replaced on-site, extending its lifespan and conserving resources. The use of plastic also streamlined several manufacturing steps, and the special sustainable plastic significantly reduces CO₂ emissions during series production.

    Scope of the Housing

    The complete housing unit of the Cubos C44E consists of four plastic parts: a lid, a housing back, and two internal covers for the power modules. The parts measure approximately 50 x 50 cm with a depth of up to 20 cm. Compactness is crucial for such a housing; it must be as compact as possible without technical issues arising.

    Challenges During the Project

    The choice of materials was a particular challenge. The plan was to use a renewable raw material for the housing. However, the necessary tests are very time-consuming, which is why the decision was made to use the current material during development. Fried’s experts are still testing other bio-based plastics containing lignin, a plant component, with the trials currently being developed towards series maturity.

    Another challenge was meeting the timeframes and ensuring compliance with legal standards. “The certification process for such a product is extremely complex and time-consuming. You need technically excellent prototypes for certification before the product release,” recalls Tepper.

    Advantages of the Injection Moulding Process

    The visible parts of the Cubos C44E are produced using the structural foam injection moulding process, allowing for a wall thickness of 8 mm, emphasizing the device’s value. These plastic parts are then painted. The logo and brand name are applied to the housing using pad printing. The internal parts are manufactured using compact injection moulding and installed unpainted. For a series production of around 2,500 units per year, the injection moulding process has proven to be the optimal solution.

    Fried as a Partner

    After completing the product design phase, Fried supported the plastic-friendly construction of the housing, tool development, testing with various materials, sampling, painting, and material testing with flame tests. The customer highlights that Fried has a clear technological advantage over other suppliers and can draw on many years of experience with well-established processes in series production. “There was nothing to complain about in terms of quality with the first series parts. The first delivery of about 130 parts was very high quality in terms of surface technology and met our expectations,” emphasizes Tepper.

    Related Links:

    Structural Foam Injection Moulding
    CUBOS C44E


    Picture 1 Copyright: CUBOS Service GmbH

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