EV Die Casting - Aluminum Motor & Battery Housings
EV die casting for aluminum motor housings, inverter enclosures, battery tray structures, and OBC housings - lightweight parts for electric vehicles.
Production Capabilities
Supporting visuals for EV die casting
Manufacturing Operations
Die casting production, tooling fabrication, CNC machining, and quality inspection at our Nanjing facility.
Component Detail
Close-up views of cast components showing surface finish, dimensional features, and application-ready quality.
Electric vehicles contain more aluminum die casting than equivalent ICE vehicles. New powertrain architectures have created entire categories of die cast components that did not exist five years ago, and the weight and range imperatives of electrification are pushing aluminum into structural and chassis applications that were previously steel.
What Makes EV Die Casting Different
T6 heat treatment requirements: BEV structural castings must meet crash safety requirements that demand yield strength only T6 treatment can provide -40-50% higher than as-cast values. T6 requires very low porosity, achievable only with vacuum-assisted HPDC (VADC). KastMfg's VADC machines support T6 structural programs.
Combined pressure tightness and thermal performance: EV cooling components -battery thermal management manifolds, motor cooling jackets, power electronics cold plates -must simultaneously contain pressurized coolant and transfer heat efficiently. A413 with VADC meets both requirements: 121 W/m·K thermal conductivity plus pressure-tight microstructure.
IP67 for high-voltage safety: Inverters, DC-DC converters, and OBC housings require IP67 sealing at the enclosure perimeter. KastMfg machines all O-ring grooves to drawing specification with CMM verification and 100% pressure testing.
EMI containment: High-voltage electronics generate significant EMI. Die cast aluminum housings provide 60-70 dB attenuation inherently; KastMfg machines flange faces to 0.01-0.02 mm flatness to ensure shield continuity at joint lines.
EV Components Produced at KastMfg
Electric Motor Housings
Motor housings must align bearing bores to within 0.02-0.05 mm (air gap uniformity = motor efficiency), contain liquid cooling at 3- bar, and achieve IP67. KastMfg produces motor housings in A380 with VADC for cooling jacket integrity, with H6 bearing bores finish-machined in a single CNC setup.
Inverter and Power Electronics Housings
IP67-sealed housings with machined IGBT mounting faces (flatness 0.01-0.02 mm for thermal contact), precision O-ring grooves, and pressure-tested coolant circuit provisions.
Battery Tray Structural Members
Large structural castings 5-15 kg in A380, T6 heat treated after VADC. KastMfg's 1,000T and 1,600T machines handle these components. Crash load requirements met through yield strength verification on T6 witness specimens.
Onboard Charger (OBC) Housings
IP67, thermal management (200-300 W heat dissipation during charging), high-voltage connector integration, power module mounting. A380 or A413 depending on cooling circuit pressure requirements.
Thermal Management Manifolds
Battery loop and motor cooling distribution manifolds. A413 + VADC for combined pressure tightness and 121 W/m·K thermal conductivity. 100% pressure tested before shipment.
EV Process Capabilities at KastMfg
| Requirement | KastMfg Capability |
|---|---|
| T6 heat treatment | VADC achieving ASTM E505 Class 1- porosity |
| Large structural castings | 1,000T and 1,600T, up to 30 kg |
| IP67 sealing | Precision O-ring grooves, CMM verified, pressure tested |
| Coolant circuit pressure tightness | A413 + VADC + 100% test |
| Motor bearing bore accuracy | H6 in single CNC setup, concentricity 0.02 mm |
| IATF 16949 | PPAP Level 1-5, full APQP |
EV Industry Trends Driving Die Casting Innovation
800V architecture: Higher voltage enables faster charging. More stringent insulation requirements affect housing wall thickness minimums and connector mounting geometry.
Silicon carbide (SiC) power modules: Junction temperatures up to 175°C versus silicon's 150°C. Higher thermal demands on housing and interface -alloy selection and interface flatness become more critical.
Structural battery integration: Battery cells integrated into the structural floor -imposing concurrent structural, sealing, and thermal requirements on one large casting.
Related Guides
- Giga casting — mega-size HPDC for EV structural parts
- Vacuum die casting — vacuum-assist for structural EV parts
- Automotive die casting — powertrain and chassis programs
- Structural die casting — high-integrity load-bearing parts
Related
EV program inquiry: casting@kastdiecast.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
Related Resources
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Case StudyCase Studies
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CapabilityQuality Control
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Process GuideDie Casting Process
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