Advanced Materials for ESS
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Galaxy: Next-Generation Design for Residential Energy Storage System

Our Galaxy demonstrator elevates residential Energy Storage System (ESS) by replacing conventional metal enclosures with lightweight, durable, and design-ready materials that combine enhanced aesthetics with long-term outdoor reliability.
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Transforming Residential ESS Beyond Metal Limitations

In the rapidly evolving renewable energy sector, conventional metal-based enclosures for residential ESS face significant limitations, including excessive weight, susceptibility to corrosion, limited design options, and high installation costs.

To explore alternatives, polycarbonate-based demonstrators are being developed to directly address these challenges. These prototypes offer inherent lightweight properties that reduce transportation carbon footprint and simplify installation while maintaining superior mechanical performance. They also illustrate how residential ESS can become easier to install, more resilient in outdoor environments, and capable of supporting advanced functionalities.

Meet Galaxy, Enabling Seamless, Elegant, and Modern Design for ESS

Amid the growing diversification of residential ESS applications in the smart energy era, the Galaxy polycarbonate demonstrator integrates aesthetic design and high-performance functionality, offering new possibilities for the next generation of residential energy storage devices. It combines Film Insert Molding (FIM) technologies to deliver seamless aesthetics and integrated functionality. The design features illuminated logo and edge lighting, a 3D surface texture, and dynamic visual displays, illustrating how functional and decorative elements can be harmoniously integrated within a single manufacturing process.

Built with these polycarbonates, the demonstrator likewise delivers reliable outdoor durability, validated through accelerated aging tests that simulate UV exposure, thermal cycling, damp heat, and environmental stresses. By replacing metal with polycarbonate, the material helps prevent oxidation and material degradation, ensuring stable long-term performance with low maintenance requirements.

Advanced Materials for ESS

By combining high-performance materials with our design and processing expertise, we empower partners to create energy solutions that not only perform better but also look better. As integrated energy storage systems become part of modern living spaces, we’re shaping smarter, lighter, and more beautifully designed solutions for the homes of tomorrow.

Thomas Derichs

Global Head of Industrial Marketing Electronics and Electrical, Engineering Plastics, Covestro

Specialized Solutions for High-Performance ESS

Building on the advantages of polycarbonate, the Galaxy demonstrator integrates a range of advanced materials engineered to deliver superior performance in various residential ESS scenarios.

Black transparent formulations combine optical clarity, flame retardancy, and weatherability, meeting UL94 V0 and F1 outdoor ratings while enabling advanced features such as illuminated status indicators and interactive interfaces.

Additional specialized grades include high-performance solutions for harsh environments; renewable-attributed grades offering low-carbon alternatives to support sustainability initiatives; and custom-colored formulations with integrated UV stabilization for lasting aesthetics and performance. Together, these developments enable manufacturers to deliver high-performance ESS that meet technical, regulatory, and environmental demands while supporting innovative product features.

Key benefits

  • Design freedom: Enables sophisticated geometries and integrated functionalities with premium aesthetics.
  • Mechanical performance: Exceptional impact resistance across extreme temperature ranges.
  • Durability: Validated through accelerated aging tests including UV, thermal, and damp heat exposure.
  • Flame-retardancy: Black transparent PC meets UL94 V0 and F1 rating requirements for outdoor applications.

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