Introduction
When designing aluminum liquid cooling plates for EV and ESS applications, the manufacturing process is never a downstream decision.
In reality, manufacturing processes directly shape geometry, reliability, cost, and long-term risk.
Choosing the wrong process often leads to problems that cannot be fixed later by design optimization alone.
1.CNC Machining: The Safest, but Not Always the Final Solution
CNC machining offers unmatched flexibility and precision.
It is often the safest option for:
- Prototypes and early-stage development
- Complex internal flow channels
- Applications with extremely high sealing requirements
However, CNC machining comes with clear limitations in volume production:
- High unit cost
- Long cycle time
- Limited scalability
For many projects, CNC is an excellent starting point — but rarely the most cost-efficient end solution.
2.Die Casting: Attractive Integration with Hidden Risks
Die casting is often considered for its high integration level and low unit cost at scale.
However, for liquid cooling applications, it introduces critical risks:
- Internal porosity that affects sealing reliability
- Difficulty in detecting internal leakage
- Increased risk during post-machining or welding
In systems where leakage tolerance is close to zero, die casting requires extreme caution.
3.Extrusion: A Robust and Underestimated Solution
Extrusion is frequently overlooked because it limits geometric freedom.
Yet for many ESS and thermal management applications, it offers key advantages:
- Dense material structure
- Excellent consistency
- Very competitive cost for high volumes
When straight flow channels are acceptable, extrusion often delivers the most stable and scalable solution.
4.Manufacturing Defines Design — Not the Other Way Around
A common mistake in early-stage design is prioritizing performance without considering manufacturability.
In real engineering projects:
- Designs must be manufacturable
- Sealing surfaces must be reliable
- Internal structures must be inspectable
A design that cannot be reliably produced and verified is not a valid engineering solution.
Conclusion
There is no universally “best” manufacturing process for aluminum liquid cooling plates.
The right choice depends on balancing:
- Thermal performance
- Production volume
- Sealing reliability
- Cost and scalability
- Overall system risk
Understanding these trade-offs early is essential for building reliable cooling solutions for EV and ESS applications.
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