EV Charging Enclosure

Consultation

For this project we needed to create an electric vehicle charging enclosure for Hypervolt, a UK based team, using our plastic fabricated enclosure solution process.

The home is Hypervolt’s target market, soon expanding into commercial and by using our fabrication process they could achieve the required features and finish needed. The smart charger is WIFI and Bluetooth enabled to work with an app, giving the end user more control and the enclosure needed to be an aesthetically pleasing design piece, whilst also allowing the end user to change the brightness, colour, charging times of the EV charger using the app. A luxury product without the premium.

Product Development

Hypervolt first approached CamdenBoss on 22^nd February 2019 and by 1^st March 2019 had their first prototype of the product. We continued to develop this product with them, providing two more rounds of prototypes and by February 2020 Hypervolt had ordered 50 enclosures.

From this point more developments were made to the product and they have since ordered many hundreds more pieces from us. The benefits of using our plastic fabrication process over other technology is that ‘there is no up-front cost with their manufacturing method so you have several advantages straight away: 1. Lower upfront capital commitment; 2. Lower cost prototyping and lower cost of iteration between design cycles.’ (Vasiliu, R. Hypervolt CTO). As they are local to CamdenBoss, they could also easily visit the factory to iron out any issues quickly.

The plastic fabricated enclosure solution was manufactured using ABS and we also added digital printing and a gasket to the enclosure too. Initially in the prototyping phase, the transparent panel was made using green acrylic with white LEDs behind, as shown in the images of the prototypes below.

This element of the design was later developed and is now made by thinning the plastic to show the coloured LEDs, allowing the customer to change the colour. Razvan on working with us saying ‘they approached the design with a set of fresh eyes; we came to them with a mechanical mock-up (external dimensions and overall shape) as well as design specification for the internals. A dedicated design engineer has been assigned to the project and ensured progress was smooth at all times. Communication was great and within less than 2 week a proof-of-life prototype was born which was pretty much 90% there’ (Vasiliu, R. Hypervolt CTO).

Final Solution

The solution was an aesthetically pleasing enclosure that suited its application. Razvan, Hypervolt’s CTO commented, ‘the finish is phenomenal - we always get excellent feedback from our customers when they open that first box (both experienced installers who work with many different EV charging products as well as our end customers): they all like both the quality of the build and the beauty of the design and finish’ (Vasiliu, R. Hypervolt CTO), which is incredible feedback.

We also found out what some of Hypervolt’s customers are saying about the product through their customer Trust Pilot Reviews:

‘Great experience having a Hypervolt installed at our property. Zero issues with charging on a 21 MY Jaguar I-Pace. Great service. Great Product. (also looks really awesome)’ (Gavin. Trustpilot.com).

‘As a Installer and a end user I have been impressed with Hypervolt from the installation to plugging my van in every night. The easy to use interface and great looking unit makes this a go to home charger I will recommend to all my customers.’ (Culley, S. Trustpilot.com)

‘The actual charger looks phenomenal and now the car is charged in a few hours. Could not be happier!’ (Saweirs, M. Trustpilot.com)

‘Despite the fact that it is a newcomer in the market of home charging, the presentation was made very professionally.’ (Polun, Y. Trustpilot.com)

‘unit looks nice too especially at night with the lights, much better than my previous unit quicker charge too, run off WiFi or 4g option!’ (Dyson, S. Trustpilot.com)

‘Love my new charger, smooth and well designed also very easy to use. Very fast and easy installation. Works really well with my new Tesla model 3. Thank you!’ (Ondrej. Trustpilot.com)

Manufactured from ABS

Product Size: W: 243 mm  D: 101 mm  H: 352 mm