Die Cast Motor Housings -End Shields, Stator Frames, and EV Motor Cases

Electric motor housings -end shields, stator frames, fan covers, and terminal boxes -represent one of the highest-volume aluminum die casting applications globally. Every NEMA and IEC frame induction motor, every servo and stepper motor, and every EV traction motor uses die cast aluminum structural and thermal components.

KastMfg has produced motor housings across motor frame sizes from NEMA 56 to 449T (IEC 63 to 315), in standard AC induction, servo, BLDC, stepper, and EV traction motor configurations.

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Parts in This Family

Part	Motor Type	Key Features
Front (DE) end shield	All types	Bearing bore H6, rabbet, conduit entry
Rear (NDE) end shield	All types	Bearing bore H6, fan cover mount
Stator frame (integral)	Small/medium NEMA	Fins, feet, terminal box
Fan cover	TEFC motors	Ventilation slots, safety screen
Terminal box body	All types	Cable entry boss, mounting feet
VFD / servo drive enclosure	Drive electronics	Heatsink fins, DIN rail, IP65
EV traction motor housing	BEV/HEV	Cooling jacket, IP67, H6 bearing bores

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Critical Dimensions and Tolerances

Feature	Specification
Bearing bore diameter	H6 tolerance: ±0.008-0.015 mm
DE/NDE bore concentricity	>=.02-.05 mm
Rabbet perpendicularity to bore	>=.02 mm/100 mm
Parting face flatness (oil seal)	0.02 mm
Cooling jacket pressure test	100% at 1.5x working pressure

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Alloy Recommendations

Application	Alloy	Key Reason
General purpose motor housings	A380	Best castability, machinability
High-efficiency or outdoor motors	A360	+18% thermal conductivity, corrosion resistance
EV motor with cooling circuit	A380 + VADC	Pressure-tight cooling jacket

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Manufacturing Process

1. Cold-chamber HPDC (160T-00T for most motor programs)
2. T5 aging available (improved yield strength for high-load mounting bracket areas)
3. T6 available for programs using VADC -required for crash-safe EV structural programs
4. CNC boring of all bearing bores in single setup (concentricity controlled)
5. CMM verification of bore diameter, concentricity, and face perpendicularity
6. Surface finishing: shot blast, powder coat, anodize, or e-coat per specification

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Industries

Industrial motors (pumps, fans, compressors, conveyors) · EV and hybrid traction motors · Servo and precision motion control · Appliance motors · Power tool motors · Agricultural electric drives

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FAQ

What bearing bore tolerance can you hold? H6 tolerance standard: ±0.008-0.015 mm on diameter. All bearing bores machined in a single CNC setup maintaining DE/NDE concentricity.

Can you produce EV motor housings with integral cooling jackets? Yes. VADC is used for porosity control at jacket walls, followed by 100% nitrogen pressure testing at 1.5x rated cooling pressure. See EV motor housing case study.

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Motor housing inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China