Die casting is mainly applied to EV structural components where integration and volume efficiency are critical.

Typical die-cast EV parts include:

• Battery pack housings and covers
• Structural shells and frames
• Non-fluid structural components

Engineering considerations for EV components:

• Suitable for high-volume production with integrated geometry
• Requires careful evaluation when sealing or thermal performance is involved
• Liquid cooling parts must be assessed for porosity and leakage risk

For liquid cooling applications in EV systems, die casting should only be selected after thorough risk and inspectability evaluation.

In automotive applications, die casting is widely used for structural and functional aluminum parts.

Typical die-cast automotive parts include:

• Structural brackets and mounts
• Transmission and chassis housings
• Engine bay aluminum shells

Why die casting for automotive components:

• Cost-efficient at high production volume
• Good dimensional repeatability
• Well suited for integrated structural designs

Die casting is selectively used in motorcycle and racing applications.

Typical applications include:

• Non-fluid structural shells
• Covers and housings without critical sealing requirements

Engineering note:

• Performance and racing components often prioritize billet CNC machining
• Die casting is generally avoided for parts with high aesthetic or sealing demands

• Liquid cooling or zero-leakage requirements
• Internal fluid channels or enclosed cavities
• Safety-critical system components
• Limited inspectability of internal defects

In such cases, alternative processes or hybrid solutions (die casting + CNC machining) may provide better system reliability.

To understand how engineers compare die casting with CNC machining and aluminum extrusion for cooling components, you may find this article helpful:
CNC vs Die Casting vs Extrusion for Aluminum Cooling Components.