Busbars. Enclosures. Motor housings. EV supply chain.

EV busbars typically copper C110 ETP or C101 OFE (for ultra-high current). Common thicknesses: 2–10 mm. Tin or silver plating for low contact resistance and corrosion protection. Tight tolerance on mounting hole locations (±0.1 mm for multi-cell stacks). Surface cleanliness matters for electrical contact. We machine, plate, and package busbars ready for ultrasonic welding to cell tabs.

EV battery packs typically require IP67 — protected against dust ingress and temporary water immersion. Achieved via: compression-gasket sealing on enclosure lid, sealed cable pass-throughs, pressure relief valves for thermal runaway safety. Higher IP68 ratings possible for submarine/marine applications. Our enclosure DFM review includes seal groove design verification.

Three approaches: (1) Cooling plates with integrated channels — aluminum with CNC-machined serpentine channels, brazed lid or friction-stir welded. (2) Finned heat sinks — extruded 6063 aluminum cut and machined to size. (3) Liquid cold plates — often aluminum casting with machined channels. We handle all three approaches depending on thermal load and package size.

EV motor housings need: precision bearing seats (±0.01 mm), integrated cooling jacket with liquid passages, sealed cover geometry, precision-machined concentricity (run-out < 0.05 mm), and often integrated resolver/sensor mounting. Typically aluminum (6061 or cast A380). Our 5-axis capability handles the integrated cooling channel geometry in single setup.

Yes — EV charging station hardware is a growing workstream. Requirements: weather-sealed IP44–IP66, UV-resistant powder coat finish, vandalism-resistant construction, cable management integrations, thermal management for continuous current operation. Typical sizes: 1500 × 800 × 300 mm for DC fast chargers. Sheet metal + machined brackets combined work.

Yes — EV OEMs typically require full traceability similar to automotive. Mill certificates per EN 10204 3.1 on all materials. Lot tracking linking parts to material heats. Inspection records archived for typical 10-year automotive retention period. FAI (AS9102 format acceptable, or PPAP level 3 for automotive) on initial production. Documentation package matches Tier-1 EV supplier expectations.