Introduction
Whether it’s a liquid cooling plate, battery housing, or thermal-management enclosure, EV thermal components must meet strict requirements for heat transfer, sealing, flatness, and dimensional accuracy.
Before mass production, engineers rely on prototyping to validate designs, confirm manufacturability, and identify risks early.
In this guide, we explain the complete process—from drawing → prototype → first batch—so EV companies understand what to expect and how to work efficiently with a supplier.
1. Step 1 — Reviewing Drawings & Understanding Design Intent
A strong prototype process always begins with engineering alignment.
Suppliers should check:
➤ Material specification (6061, 3003, ADC12, etc.)
➤ Sealing areas & gasket interfaces
➤ Channel geometry for cooling plates
➤ Wall thickness & thin-wall risks
➤ Tolerance stack-up across large parts
➤ Critical-to-function dimensions
Why this matters
Thermal components often fail not because of machining issues, but because the design itself has hidden risks.
A mature supplier will provide DFM suggestions before cutting any metal.
2. Step 2 — DFM Review & Optimization
DFM (Design for Manufacturability) is an essential stage, especially for cooling plates and battery housings.
Typical DFM recommendations include:
➤ Adjusting channel radii to improve machining
➤ Increasing rib thickness for stability
➤ Reducing tolerance where not needed
➤ Reinforcing thin walls
➤ Choosing appropriate finishing processes
➤ Selecting the right machining strategy
Goal of DFM
To make the part manufacturable, stable, and cost-efficient without compromising performance.
3. Step 3 — Selecting the Right Prototyping Method
Different EV components require different prototyping methods.
For Liquid Cooling Plates
➤ CNC machining of full channels
➤ Bonded plates for flow testing
➤ FSW samples for structural validation
For Battery Housings
➤ CNC machining from billet
➤ 3D-printed test fixtures (non-functional)
➤ Hybrid prototypes: partial die-cast + CNC
For Electronic Enclosures
➤ Machined aluminum blocks
➤ Temporary lids or covers for thermal tests
Key principle:
Prototypes must simulate the final mass-production performance as closely as possible.
4. Step 4 — CAM Programming & Machining Strategy
This stage determines the accuracy, flatness, and surface quality of the prototype.
Suppliers must define:
➤ Tool paths
➤ Cutting parameters
➤ Fixturing method
➤ Deburring strategy
➤ Surface finishing preparation
Typical machining challenges for thermal parts:
➤ Maintaining channel depth uniformity
➤ Preventing thin-wall deformation
➤ Achieving flat sealing surfaces
➤ Avoiding chatter on large aluminum faces
A strong supplier adjusts the machining strategy through simulation and experience.
This is where raw aluminum becomes the first real, testable part.
Suppliers perform:
➤ Rough machining
➤ Finishing passes
➤ Channel machining (for cooling plates)
➤ Critical surface machining
➤ Threading & pocketing
➤ Deburring
Outputs:
➤ Prototype parts
➤ Initial dimensional reports
➤ Photos & progress documentation
At this stage, design weaknesses are usually revealed, allowing for early improvement.
6. Step 6 — Inspection & Function Testing
Thermal components require strict quality checks.
Critical inspections include:
➤ CMM measurement of sealing surfaces
➤ Channel-depth verification
➤ Flatness measurement
➤ Thread gauge testing
➤ Surface roughness testing
➤ Leak/pressure testing (for cooling plates)
Typical functional tests:
➤ Flow-rate testing
➤ Pressure endurance
➤ Thermal simulation validation
7. Step 7 — Design Adjustments & Iteration
Most EV prototypes go through 2–3 iterations before freezing the design.
Iteration goals:
➤ Improve sealing stability
➤ Reduce machining time
➤ Adjust tolerances
➤ Improve coolant flow distribution
➤ Strengthen structural weak points
Suppliers and engineers work together to push the design toward mass-production feasibility.
8. Step 8 — First Batch Production (20–200 pcs)
When the design is 90%–100% validated, the program moves into the first batch.
First-batch objectives:
➤ Validate consistency
➤ Test finishing stability
➤ Optimize machining time
➤ Confirm tolerances in larger batch
➤ Finalize packaging & logistics requirements
This stage determines whether the design and manufacturing strategy are stable enough for scaling.
9. When to Switch from CNC → Die Casting + CNC
Many EV customers start with CNC prototypes and eventually move to die casting.
Switching conditions:
➤ Volume exceeds 800–1,500 pcs/year
➤ Design is frozen
➤ Complex internal features needed
➤ Cost reduction is required
Die casting reduces unit price and enables more complex features, but CNC must still finish critical surfaces.
Conclusion
Prototyping EV thermal-management components requires a clear and structured process—from drawing review to DFM, machining strategy, inspection, and first-batch validation.
A strong supplier behaves like an engineering partner, helping EV companies reduce risk, improve performance, and accelerate launch timelines.
Choosing a supplier with strong DFM, CMM, machining capability, and clear communication is the key to a smooth development cycle.
👉“Learn more about our EV components.