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01274 707030 CASE STUDY: UBITRICITY
CASE STUDY: UBITRICITY
Vacuum Formed EV Charging Doors for Ubitricity
As electric vehicles (EVs) become more common across the UK, so does the need for accessible, on-street charging solutions. Enter Ubitricity, the leading EV charging provider and member of the Shell Group, who are transforming everyday street lighting columns into convenient EV charging points.
To bring this innovative solution to life, Ubitricity partnered with HALDO, specialists in engineering and electrical feeder pillars, to produce the complete charging door units. In turn, Haldo’s Sister company, Bradford based FRANCIS WARD was tasked with vacuum forming the door bodies. The result? A cost-effective, durable, and scalable product now helping EV drivers across the UK charge their vehicles from their nearest lamppost.
Project Requirements
FRANCIS WARD was brought in by sister company Haldo to vacuum form the external charging access doors, a key part of the complete lamppost charging unit. The components needed to:
- Be weather-resistant and durable for 24/7 outdoor exposure
- Offer a secure, tamper-resistant structure for public safety
- Fit precisely into the lamppost column door opening
- Be lightweight for ease of installation
- Be cost-effective to manufacture at scale
- Ease of fitting (which takes under 30 minutes in most locations)
- Blend visually into urban and residential environment
Our Solution: Vacuum Forming in ABS
Francis Ward recommended vacuum forming using ABS, a thermoplastic known for its durability and clean finish.
- ✅ Impact Resistance – Ideal for public environments
- ✅ UV and Weather Resistant Grades – For long-term outdoor use
- ✅ Lightweight, Yet Strong – Reduces load, simplifies handling
- ✅ Good Surface Finish – Clean look, supports branding or colour
- ✅ Recyclable – Supporting sustainability goals
Manufacturing Process
FRANCIS WARD managed the production for the vacuum formed parts, from prototype to scale-up:
- Prototyping
3D printed prototypes were produced to test fit, finish, and functional integration. - Vacuum Forming
Sheets of UV-stable ABS were heated and formed over precision tooling to shape the door components. - Robot Trimmed
Each part was trimmed to tight tolerances to ensure a perfect fit into the lighting column frame. - Quality Control
Each unit underwent rigorous quality checks to meet Francis Ward’s manufacturing standards. - Delivered to Haldo
Finished parts were delivered to Haldo to be assembled and finished with the required components.
Results
- 📈 Rapid Production at Scale – Supporting Ubitricity’s national rollout
- 🎯 Consistent Fit & Finish – Batch after batch of precision-matched parts
- 🌍 Deployed Nationwide – Now in active use on UK streets, enabling sustainable transport
Client: Ubitricity
Vacuum Forming by: Francis Ward
Manufactured by: Haldo Developments Ltd
Deployed in: Public Lighting Columns Across various UK Locations
About: Ubitricity
Ubitricity is the largest provider of EV charge points with over 10000 charging units deployed to date, a pioneer in on-street EV charging infrastructure. By retrofitting existing street furniture—particularly lighting columns—they enable EV drivers to plug in where they park, without the need for new charging bollards or roadside construction.
With thousands of installations already deployed across UK cities, Ubitricity’s mission is simple:make EV charging accessible, affordable, and everywhere.
Conclusion
This project showcases the strength of collaboration between FRANCIS WARD, Haldo, and Ubitricity in bringing to market a smart, scalable solution for the UK’s growing EV infrastructure.
Thanks to vacuum forming expertise and efficient production capabilities, FRANCIS WARD continues to play a key role in shaping the future of sustainable transport—one lamppost at a time.