EV & New Energy Manufacturing
Precision Manufacturing for EV & New Energy Components
Manufactured for high-voltage distribution, battery systems, thermal management, and structural performance. PartsMake helps engineering and procurement teams move custom metal and plastic components from design to dependable production.
98%+
IACS conductivity target for busbars
<0.05 mm
Cooling plate flatness target
CMM
Critical dimensional verification
Built around your application
Material, heat transfer, electrical safety, and assembly tolerances reviewed before production.
Specialized capabilities
Manufacturing engineered for new energy systems
We do not simply machine parts. Our process accounts for electrical conductivity, thermal dissipation, sealing performance, material behavior, and the tolerances required for reliable assembly.
Busbars & Connectors
High-current copper and aluminum busbars produced through precision bending, punching, and CNC machining. Insulation coating and nickel or tin plating support electrical safety and corrosion resistance.
Battery Housings & Structural Parts
CNC-milled and sheet metal enclosures with accurate mounting points, consistent wall thickness, airtight sealing interfaces, and structural protection against physical impact.
Cooling Plates & Thermal Management
Cooling plates and heat sinks manufactured with tight flatness tolerances for consistent thermal interface material contact. Leak testing helps prevent coolant failure in critical systems.
Technical specifications
Performance metrics aligned to EV requirements
These standard manufacturing metrics are adjusted to your drawings, application requirements, and material certifications.
| Component Type | Primary Materials | Key Manufacturing Metrics | Quality & Safety Controls |
|---|---|---|---|
| Busbars | Copper C11000, Aluminum 6063 | Conductivity > 98% IACS; ±0.1 mm bend tolerance | Insulation resistance; pull-force testing |
| Cooling Plates | Aluminum 6061 / 5052 | Surface flatness < 0.05 mm; high-speed CNC | Helium or air-pressure leak detection |
| Battery Housings | Aluminum, steel, engineering plastics | Dimensional accuracy; wall-thickness uniformity | Seal integrity; structural stress analysis |
| Connectors | Brass, copper, PEEK, nylon | Thread precision; hole positional accuracy | Thread gauging; visual inspection |
| Structural Parts | Aluminum, stainless steel | ±0.02 mm tolerance; concentricity | CMM inspection; hardness testing |
DFM & risk mitigation
Reduce manufacturing risk before material procurement
Manufacturing failures in EV systems are costly. Our engineering team reviews CAD files and drawings early to identify production risks, improve manufacturability, and protect performance.
Submit CAD for Review01
Material Selection
Confirm alloys meet thermal conductivity and electrical resistance requirements.
02
Geometric Tolerances
Identify difficult-to-hold features and suggest cost-conscious adjustments.
03
Assembly Interfaces
Verify mating surfaces for connectors, housings, and cooling plates.
04
Production Scalability
Plan an efficient path from prototype to low-volume and repeat production.
Integrated quality assurance
Testing beyond visual inspection
Every production run is supported by application-specific checks so parts are ready for immediate assembly and dependable field operation.
Leak Testing
Pneumatic or helium leak testing verifies seal integrity under pressure for cooling systems.
Electrical Verification
Conductivity and resistance checks confirm busbars and connectors meet electrical load specifications.
Dimensional Accuracy
CMM inspection and calibrated gauging support consistent fitment in automated assembly lines.
Surface Finishing
Anodizing, powder coating, and plating provide corrosion resistance and dielectric strength.
Production lifecycle
From prototype to repeat production
Whether you are validating a battery module or scaling charging infrastructure components, we manage the transition from first parts to ongoing supply.
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1
Prototype
Fast-turnaround CNC machining and 3D printing validate form and fit.
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2
Engineering Samples
Pilot runs use production-intent materials and methods to test thermal and electrical performance.
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3
Low-Volume Production
Optimized tooling reduces per-part costs while maintaining application requirements.
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4
Repeat Production
Consistent supply chain management supports ongoing assembly needs.
Frequently asked questions
Answers for your next EV component project
Request a manufacturing review
Turn your EV component design into a production-ready plan
Submit your CAD files and technical drawings. Our engineering team will review your requirements and provide a quote, lead-time guidance, and DFM feedback.
Email your files:
Office address:
Include these project details
- ✓3D CAD files, STEP or IGES preferred
- ✓2D drawings with tolerances
- ✓Material specifications
- ✓Required surface treatments or coatings
- ✓Estimated annual volume or batch size
Ready to discuss your application?