The electric vehicle (EV) revolution is changing the way we design and manufacture automotive components.
From battery housings to cooling plates and charging modules, each part must meet new demands for thermal efficiency, weight reduction, and safety.
Here’s how modern EV automotive components are engineered — and how suppliers like Wometal help solve these design challenges.
1. Lightweight Design Is Critical
Every gram saved extends EV driving range.
That’s why most EV components are made from aluminum alloys instead of steel.
Aluminum provides an excellent balance of strength, conductivity, and corrosion resistance — ideal for structural and heat management applications.
Common uses include:
- Battery pack enclosures
- Cooling plates and heat sinks
- Inverter and motor housings
- Charging connectors and brackets
At Wometal, we use both CNC machining and die casting to produce lightweight, precision aluminum parts that meet OEM standards.
2. Thermal Management and Cooling Systems
Heat management is one of the most critical challenges in EV design.
Excess heat reduces battery life and motor efficiency — and in extreme cases, it can lead to safety risks.
Key thermal solutions include:
- CNC machined cooling plates with internal fluid channels
- Die-cast aluminum housings for efficient heat dissipation
- Liquid cooling modules for battery and inverter systems
Our engineers optimize wall thickness, channel geometry, and surface finish to maximize cooling performance while maintaining structural integrity.
3. Electrical Safety and Insulation
Unlike conventional vehicles, EVs handle high-voltage systems (400V–800V).
That means every component — from housings to connectors — must ensure electrical insulation and protection.
Design considerations:
- Precision fit and sealing for waterproofing (IP67 or higher)
- Anodized or coated surfaces for corrosion and arc resistance
- Machining tolerances within ±0.02 mm for sealing grooves and threads
We also provide custom gasket designs and non-conductive coatings to enhance safety and performance.
4. Manufacturing Challenges and Solutions
Producing EV components requires tight process control and flexible manufacturing.
Main challenges include:
Our experience in both CNC machining and die casting ensures that every EV component achieves both precision and repeatability.
5. Material Selection for EV Components
The most commonly used materials for EV structural and thermal components include:
- 6061 / 6082 Aluminum — excellent strength and machinability
- ADC12 Aluminum Alloy — ideal for die casting and thin-wall designs
- Copper and Brass Inserts — for conductive interfaces
- Composite or plastic housings — for insulation and weight reduction
Material selection affects not only performance but also the manufacturing process and cost efficiency.
6. Real Case: Battery Housing for Electric Bus
For a European electric bus manufacturer, Wometal supplied a large-format battery housing with integrated cooling channels.
Highlights:
- Size: 900×600×120 mm aluminum enclosure
- Process: Die casting + precision CNC machining
- Features: Liquid channel machining, leak-proof testing, anodized finish
- Outcome: Reduced unit weight by 25% and improved thermal efficiency by 18%
The project demonstrates our ability to combine design optimization and precision manufacturing for real-world EV applications.
7. Why Choose Wometal for EV Components
EV projects demand a manufacturer with deep engineering and process control experience.
At Wometal, we offer:
- Full in-house CNC machining and die casting
- Simulation support for mold flow and thermal design
- Quality control with CMM and leak testing
- Material traceability and PPAP documentation
- Experience with EV, hybrid, and battery systems
We help OEMs and tier suppliers develop reliable, efficient, and scalable EV component solutions.
Conclusion
The shift to electric mobility brings new engineering challenges — and new opportunities.
By combining lightweight materials, advanced manufacturing, and rigorous testing, Wometal helps EV manufacturers achieve higher efficiency, safety, and sustainability in every component.
👉 “Learn more about our automotive components.