Battery Energy Storage System (BESS) Solutions
Mercury Plastics supports Battery Energy Storage Systems (BESS) manufacturers with custom thermoplastic solutions engineered to manage fluids, withstand temperature extremes, and perform reliably inside complex battery assemblies.
Engineering Thermoplastic Solutions for Demanding BESS Environments
Battery Energy Storage Systems operate under highly demanding conditions where safety, reliability, and performance are non-negotiable. Components used inside BESS assemblies must address a unique set of challenges, including:
Thermal Extremes and Heat Management
BESS systems experience wide temperature swings during charging, discharging, and idle states. Thermoplastic components must maintain dimensional stability and mechanical integrity under sustained thermal stress.
Fluid Management and Leak Prevention
Cooling fluids and thermal management systems rely on dependable routing and sealed connections. Even minor leaks can compromise performance, safety, and system uptime.
Space Constraints and Complex Routing
Chemical and Environmental Exposure
Materials must withstand exposure to coolants, electrolytes, and environmental factors without degradation over long service lifecycles.
Scalability and Manufacturing Consistency
As BESS deployments grow, manufacturers need production partners that can scale reliably while maintaining tight tolerances and repeatable performance.
BESS Applications
Mercury Plastics manufactures thermoplastic components and assemblies used throughout Battery Energy Storage Systems, including:
Custom extruded tubing for fluid circulation, cooling, and thermal management systems
Formed tubing and routed assemblies designed to fit within space-constrained battery enclosures
Overmolded connections integrate fittings directly onto tubing to reduce joints and potential leak paths
Multi-material assemblies combining flexible and rigid elements to optimize performance and installation
Thermoplastic components designed for long-term durability inside enclosed, high-temperature environments
These solutions are commonly used in liquid-cooled battery packs, energy storage enclosures, and supporting thermal management systems.
BESS Applications
Mercury Plastics manufactures thermoplastic components and assemblies used throughout Battery Energy Storage Systems, including:
Custom Extruded Tubing
For fluid circulation, cooling, and thermal management systems
Formed Tubing and Routed Assemblies
Designed to fit within space-constrained battery enclosures
Overmolded Connections
Integrate fittings directly onto tubing to reduce joints and potential leak paths
Multi-Material Assemblies
Combining flexible and rigid elements to optimize performance and installation
Thermoplastic Components
Designed for long-term durability inside enclosed, high-temperature environments
These solutions are commonly used in liquid-cooled battery packs, energy storage enclosures, and supporting thermal management systems.
Proven Products Designed for BESS
Mercury Plastics has a long history of turning bold ideas into proven products. Years of dedication to solving client challenges have led to proprietary technologies that are now recognized across the industry.
Click-Connex Connections
Merflex® PEX OT® Refrigerator Water Supply Line
Our Approach
Integrated Plastics Production for BESS Systems
BESS components rarely rely on a single manufacturing process. Performance, safety, and reliability depend on how multiple processes work together as a unified system. Mercury’s vertically integrated plastics production model allows BESS manufacturers to consolidate suppliers and simplify development.
Extrusion (Profile and Tubing)
Mercury produces precision extruded tubing and profiles engineered for consistent wall thickness, dimensional stability, and material performance required in thermal and fluid management systems.
Electron Beam Crosslinking
In-house electron beam processing enhances thermoplastic performance by improving heat resistance, mechanical strength, chemical resistance, and long-term durability, making it well-suited for demanding BESS environments.
Forming & Fabrication
Formed tubing enables complex routing through compact battery assemblies while reducing the need for fittings and joints. Fabrication processes such as cutting, welding, and secondary operations deliver installation-ready components.
Injection Overmolding
Overmolding integrates connection points, seals, and features directly onto tubing, reducing assembly steps while minimizing potential leak paths.
Air-Core® Molding
For applications requiring complex geometries not achievable through traditional blow molding, Air-Core® molding supports innovative designs without excessive tooling or part count.
Fewer components, fewer leak paths, improved thermal performance, and a production partner capable of supporting programs from early development through high-volume manufacturing.
Engineering Partnership From Concept Through Production
No two projects are the same, and that’s exactly where our team excels. Our engineers work as an extension of your team to:
Evaluate performance challenges and identify root causes
Recommend materials and processes based on mechanical, thermal, and chemical requirements
Prototype rapidly to validate concepts
Integrate multiple manufacturing steps (extrusion + forming + overmolding + cross-linking) into a single, optimized solution
Scale cost-effectively from early samples to high-volume production
This cross-disciplinary engineering approach is what enables Mercury Plastics to design custom solutions that achieve better performance at a lower overall system cost.
Related Industry: Plumbing
Many of the manufacturing principles applied in BESS programs are shared with Mercury’s work in the plumbing industry, where leak prevention, material stability, and integrated production are equally critical.
Get Started with Mercury Plastics
Discover how Mercury Plastics can help you improve product performance, reduce costs, and accelerate time-to-market.