Revolutionizing New Energy Vehicle Components with Precision Manufacturing
Revolutionizing New Energy Vehicle Components with Precision Manufacturing
Blog Article
The Challenge: Demands of Modern Electric Vehicles
As a Tier 1 supplier for leading EV manufacturers, we faced critical challenges in producing complex components:
- Ultra-thin wall requirements (0.8mm) for weight reduction
- ±0.01mm tolerance on mating surfaces for EMI shielding
- 96-hour salt spray corrosion resistance (ASTM B117)
- High-volume production (50,000+ units/month)
Integrated Manufacturing Solution
1. Advanced Zinc Die Casting
Our zinc die casting mold technology delivers:
- 98.5% dimensional consistency across batches
- 0.4mm minimum wall thickness capability
- Ra 1.2µm surface finish as-cast
2. Precision CNC Machining
Post-casting CNC machining service achieves:
- ±0.005mm positional accuracy
- 0.003mm flatness on critical surfaces
- Automated CMM verification
Project Results: Charging Port Housing Case Study
| Parameter | Requirement | Achieved |
|---|---|---|
| Weight | ≤220g | 198g |
| Surface Roughness | Ra ≤1.6µm | Ra 1.2µm |
| Thermal Cycling | -40°C to +125°C | 500 cycles passed |
Customer Endorsement
"The integrated approach reduced our development timeline by 32% while improving first-pass yield from 78% to 95%.
The zinc die casting and
CNC machining synergy
delivered perfect mating surfaces for our 800V charging systems."
Technical Advantages
- 60% faster cycle time vs. aluminum alternatives
- 0.002mm/mm CTE matching for thermal stability
- Full IATF 16949 certified process chain