What Goes Into a Custom Solar Storage System
A custom solar energy storage product contains multiple separate structural enclosures — each housing a different electronic or mechanical subsystem. We manufacture every one of those enclosures and the fluid components that connect them:
Controller Housing
Solar charge controller enclosure — UV-rated ABS or ASA for outdoor installations, with vent and connector cutouts.
Controller housing →BMS Enclosure
Battery management system housing with PCB mounting, thermal features and IP-rated sealing grooves.
BMS enclosure →Display Module Housing
Monitoring screen bezel and front-panel cover with precision display cutout and clear polycarbonate window.
Display housing →Control Panel
Operator interface panel with button cutouts, indicator windows and cable entry features.
Control panel →Fluid Fittings
Cooling manifolds, liquid connectors and threaded fittings for liquid-cooled energy storage assemblies.
Fluid components →Full Assembly
All enclosures manufactured and assembled together — fit-verified before shipment, ready for electronics.
Assembly →
How a Complete Solar System Build Works
Send the reference
A reference product, competitor unit, photos from all angles, or a concept sketch with dimensions.
Measure & model all enclosures
Every housing and enclosure is measured and modelled in CAD — free with your quote. We capture thermal clearances, connector positions, and PCB mounting features.
Confirm drawings
You review dimensional drawings for each enclosure. We adjust sealing grooves, vent positions, PCB boss heights and material specifications before production.
Manufacture the full set
Prototype runs in CNC machining and vacuum casting. Production runs in injection molding or sheet metal fabrication depending on enclosure type.
Assemble & verify fit
All enclosures and panels are assembled and checked — connector alignment, panel gaps and mounting positions — before packing.
Ship — ready for electronics & battery
The complete structural assembly ships worldwide. Your team integrates the electronics, BMS board, battery pack and firmware.
We make the structure — you integrate the electronics. We are not a BESS brand and do not sell complete systems with cells and firmware. We manufacture the physical enclosures, housings and fluid components that your product needs — to your design or from a reference product.
Example: What We Make for a Compact Solar Power Kit
A typical compact all-in-one solar power kit — 10 W panel, 18650 battery pack and controller integrated in a single weatherproof unit — contains three categories of structural parts. Here is how that breaks down:
| Structural part | What it does | Material | We make it? |
|---|---|---|---|
| Front outer shell | Frames the solar panel; front face of the unit; carbon-fibre texture | UV-stable ASA or ABS | ✓ Yes |
| Back housing | Battery compartment with cell dividers, PCB bosses, cable routing, IP66 sealing groove | ASA or PC/ABS | ✓ Yes |
| Controller / BMS section | Integrated PCB housing with USB-A / USB-C / DC connector cutouts and LED indicator window | ABS or ASA | ✓ Yes |
| Mounting bracket interface | Keyhole slots, bolt bosses and binding-strap channels moulded into the back housing | Integral with back housing | ✓ Yes |
| Solar cells (10 W panel) | Photovoltaic energy generation | Monocrystalline silicon | ✗ Not our scope |
| 18650 battery cells | Energy storage (25 000 mAh) | Lithium-ion | ✗ Not our scope |
| BMS / controller PCB | Charge control, protection, USB output | Electronics | ✗ Not our scope |
The product shown above is IP66-rated and weighs 1.36 kg — both requirements that directly shape the structural enclosure design: ASA for UV resistance, a precision O-ring groove for IP66, and wall thickness calculated to hit the target weight. These are the kinds of spec decisions we work through with you at the CAD confirmation stage.
Fluid Components — A Unique Advantage
Liquid-cooled solar storage systems need more than enclosures. They need cooling manifolds, threaded fittings, flow connectors and custom-machined fluid-carrying parts. We manufacture all of these alongside the structural housings — using the same CNC and machining capabilities that produce our adapters and fluid fittings. One supplier covers both the enclosures and the fluid circuit.
Frequently Asked Questions
Typically: solar controller housing, BMS enclosure, display module housing, control panel, and — for liquid-cooled systems — cooling manifolds and fluid fittings. EKINSUN manufactures all of these individually or as a matched set.
Yes. We manufacture the full structural set as a matched batch, verify fit, and ship the complete assembly ready for electronics integration.
We manufacture structural enclosures and housings — not the complete electrical system. Clients come to us when they are designing their own product and need the physical structure made. They integrate their own electronics, battery cells, BMS board and firmware.
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Quote — Complete System Build
Reference product, photos or sketch. Engineers reply in 24h.