Introduction
As electric vehicles (EVs) continue to evolve, the components inside battery packs, cooling systems, and power electronics must meet increasingly demanding requirements.
EV aluminum components require precision machining, thermal optimization, sealing performance, structural strength, and surface consistency—all within tight timelines and cost constraints.
This article outlines the top design challenges faced when developing EV components and the manufacturing solutions that ensure reliable, high-performing parts.
1. Challenge: Achieving Structural Strength With Lightweight Designs
EV components must remain strong while staying lightweight.
This creates engineering conflicts, especially in:
- Battery pack housings
- Structural brackets
- High-voltage enclosures
- Cooling plate covers
Issues engineers face:
➤ Thin walls reduce weight but introduce deformation risks
➤ Complex ribbing patterns are hard to machine
➤ Strength requirements vary across pack zones
➤ Different materials respond differently to heat and finishing
Manufacturing Solutions
➤ Use FEA to validate and refine ribbing
➤ Combine die casting + CNC machining for accuracy
➤ Add temporary support ribs during machining
➤ Select appropriate alloys (e.g., 6061 for strength, ADC12 for castability)
2. Challenge: Maintaining Tight Tolerances Across Large Components
EV housings and plates are large, sometimes exceeding 400–800 mm.
Achieving tight tolerances on large surfaces is one of the hardest machining tasks.
Common issues:
➤ Flatness deviations
➤ Tolerance stack-up
➤ Surface vibration/chatter
➤ Multi-side machining misalignment
Manufacturing Solutions
➤ Machine from a single reference plane
➤ Use precision fixturing and vibration damping
➤ Apply finishing passes only after rough machining
➤ Perform CMM inspection on all sealing zones
3. Challenge: Sealing Performance for Battery and Thermal Components
Sealing failures are the #1 cause of EV component defects.
Parts affected include:
- Battery enclosures
- Cooling plates
- Liquid channel covers
- Electronics housings
Typical sealing problems:
➤ Poor flatness
➤ Rough tool marks
➤ Incorrect groove geometry
➤ Deformation during anodizing
Manufacturing Solutions
➤ Machine sealing surfaces last
➤ Use 5-axis strategies for uniformity
➤ Control surface roughness (Ra < 0.8 μm for gaskets)
➤ Validate via CMM + pressure/leak testing
4. Challenge: Complex Cooling Channel Designs
Cooling plates are critical for EV thermal management.
But multi-path channels introduce machining and assembly challenges.
Engineering difficulties:
➤ Maintaining uniform channel depth
➤ Achieving smooth transitions to prevent turbulence
➤ Ensuring wall thickness stability
➤ Preventing leaks under pressure
Manufacturing Solutions
➤ Use high-precision end mills for channel cutting
➤ Apply optimized CAM tool paths
➤ Perform channel-depth inspection
➤ Bonded or FSW structures when appropriate
➤ Pressure testing each plate individually
5. Challenge: Material Limitations and Alloy Behavior
Typical problems:
➤ ADC12 die-cast porosity
➤ 6061 distortion after heavy machining
➤ 3003 soft material deformation
➤ Different anodizing color reactions
Manufacturing Solutions
➤ Choose alloys based on function, not cost
➤ Apply stress-relief operations
➤ Use vacuum die-casting to reduce porosity
➤ Perform pre-finishing test samples for color consistency
6. Challenge: Finishing Quality and Consistency
EV components frequently require finishing:
- Anodizing
- Hard anodizing
- Powder coating
- Conductive coatings
- Sandblasting
Common finishing problems:
➤ Color variation
➤ Thickness inconsistency
➤ Dimensional deviation
➤ Post-finishing warpage
Manufacturing Solutions
➤ Pre-control surface roughness before finishing
➤ Batch-control anodizing for uniform color
➤ Mask critical dimensions before coating
➤ Verify post-finishing dimensions with CMM
7. Challenge: Scaling From Prototype → Mass Production
A major challenge for EV startups and engineering teams is transitioning from:
1–10 pcs prototypes → 20–200 pcs first batch → 1,000+ pcs mass production
Scaling issues include:
➤ Cycle-time optimization
➤ Tool wear & consistency
➤ Fixture repeatability
➤ Cost reduction strategies
➤ Incorporating die casting
Manufacturing Solutions
➤ Switch from billet machining → die casting + CNC
➤ Automate inspection where possible
➤ Adjust tolerances for mass production
➤ Build custom fixtures for stability
8. Challenge: Communication and Engineering Collaboration
EV projects fail more due to communication than manufacturing issues.
Signs of a strong supplier:
➤ Provides engineering drawings/comments
➤ Responds quickly to technical questions
➤ Shares machining strategies
➤ Offers DFM feedback early
➤ Provides CMM inspection records proactively
Red Flags 🚩
➤ “Everything is okay” without reviewing drawings
➤ No DFM suggestions
➤ Unclear machining strategy
➤ No inspection capability
Conclusion
EV components face unique engineering and manufacturing challenges due to their structural complexity, thermal requirements, and safety-critical functions.
The right manufacturing partner can overcome these challenges through:
- Strong engineering support
- Advanced CNC & die-casting capability
- Proper machining strategies
- Reliable QC and finishing control
- Clear communication and scalability
Choosing the right supplier ensures safer, more reliable EV systems—and faster time to market.
👉“Learn more about our EV components.