5 Ways Smarter Packaging Powers the EV Aftermarket

This surge is reshaping the automotive aftermarket. With key EV component costs climbing——raw‐material prices for batteries  jumped over 100% since 2021—and persistent labor shortages squeezing operations, suppliers face unprecedented margin pressure. At the same time, direct to consumer (DTC) demands for same- and next-day delivery across hundreds of SKUs add further complexity.

Smarter packaging needs to go beyond mere product protection. Companies need to  create a future-forward fulfillment strategy that accelerates throughput, reduces damage, and aligns with corporate sustainability objectives. 

Here are five ways Pregis helps you stay ahead in the EV aftermarket parts boom:

1. Custom-Fit Protection for High-Value Parts

EV battery packs, powertrain control units, and headlamp assemblies come in complex shapes and carry significant value. With Pregis IntelliPack® foam-in-place systems, liquid foam molds precisely around each SKU, immobilizing it in transit and reducing the likeliness of damage. IntelliPack barcoding functionality ensures consistent protection across diverse product lines by identifying the exact bag size, foam ratio and molding sequence, eliminating guesswork and streamline operations. 

2. Protect EV Surfaces with Films & Foam Wraps

EV exterior and interior components—such as digital cabin displays, painted charging ports, chrome trim, bumper fascias, and trunks—require flawless finishes upon arrival. Two complementary solutions deliver this precision protection:

• Temporary surface films: Solvent- and water-based films like Pregis PolyMask™ Temporary Protective Films adhere securely to high-value parts, guarding against scratches and marring during manufacturing, storage and transit. The film peels away residue-free, preserving showroom-quality surfaces.
• Foam wraps for exterior parts: Bumper Guard & PE foam wraps slip over irregular shapes and conform tightly to contours, providing an abrasion-resistant barrier during automated handling and shipping.

3. Inflatable Chambers for Sensitive Electronics

Pregis AirSpeed® ChamberPak® creates robust air cushions that can be customized to each part’s profile—ideal for EV components like sensor arrays and lighting modules. The system dispenses a preformed film bag and inflates individual air chambers around the contours of the item. Lightweight yet sturdy, these inflatable barriers provide superior drop protection and air retention without excess bulk. By implementing this strategy, a leading automotive OEM turned $9.8 million in losses on headlight returns into nearly $5 million in annual savings. 

4.  Help EV Owners Recycle Packaging at Home

Pregis EasyPack® paper systems  deliver sustainable cushioning for EV parts with precision. A sturdy paper coil base holds heavy battery modules and electronics securely in place, layered paper pads around the sides and top prevent any shifting—especially on sharp or uneven edges. Once the parts are out, EV owners can simply toss paper into the bin with their other curbside recyclables. Using recyclable solutions helps you meet your sustainability targets and gives you an edge at checkout—over 60% of shoppers say they’d pay extra for products in recyclable packaging.

5. Data-Driven Packaging Audits and Testing for Continuous Improvement

A one-time audit won’t suffice in a dynamic EV market. Pregis offers comprehensive packaging assessments and testing that analyze DIM inefficiencies, order profiles, and damage trends to help future-proof your fulfillment. We identify packaging solutions that reduce costs, accelerate throughput, and adapt to the evolving mix of SKUs and shipment profiles across channels.

Ready to Power Your EV Fulfillment? 

As your strategic partner, Pregis delivers specialized solutions that tackle these EV-specific challenges head-on.The EV aftermarket is here—and it moves fast. By partnering with Pregis, you can future-proof your fulfillment strategy and keep pace with rapid EV growth.

Connect with a Pregis rep today to schedule a no-obligation packaging assessment and discover the smarter way to ship EV parts.