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Precision Aluminum Components for a US EV Battery and Control System

2026-09-24

The Project

A US-based electric vehicle supplier was developing a new battery management and electronic control system and needed precision aluminum components to house and protect the sensitive electronics. These parts had to fit into a tightly packaged vehicle architecture where every millimeter counted. The client was working against an aggressive development timeline and needed production-ready components fast—without sacrificing the dimensional accuracy and long-term reliability that automotive applications demand.

The Challenge

The project had four specific requirements that had to be met simultaneously.

High dimensional accuracy. The components featured complex mounting geometries, precision sealing surfaces, and tight-tolerance interfaces where they would mate with the battery pack and control modules. Any deviation would cause assembly interference or compromise the environmental seal.

Complex structural design. The parts included thin-wall sections for weight savings, internal ribs for structural support, and intricate outer profiles that had to be manufactured as-cast and then finished to precise dimensions. Standard processes would struggle with the combination of complexity and accuracy.

Reliable long-term performance. These components would live inside a vehicle for years, exposed to thermal cycling, vibration, and potential moisture ingress. They could not warp, crack, or corrode over the service life.

Fast prototype validation. The client’s program timeline left little room for iterative tooling changes or lengthy supplier qualification cycles. They needed parts that would pass validation quickly and transition smoothly into mass production.

Our Approach

We started before cutting any metal, reviewing the client’s design for manufacturability to identify potential issues in casting fill, machining access, and dimensional stability.

DFM engineering review. We analyzed the CAD models and proposed adjustments to wall thickness transitions, draft angles, and gating locations that would improve casting quality without changing the part’s functional geometry. This upfront review prevented costly tooling rework later.

Prototype development. Using the refined design, we developed prototype tooling and produced sample parts for the client’s fit-check and functional testing. The prototypes were machined and finished to production intent, giving the client confidence that the final process would deliver the same results.

Aluminum casting. We used high-pressure aluminum die casting to form the complex housing geometry, including internal features that would have been prohibitively expensive to machine from solid. The casting process was optimized to minimize porosity in critical sealing areas.

CNC machining. After casting, we precision-machined mating surfaces, threaded holes, and sealing flanges to achieve the tight tolerances required for assembly. This two-stage approach—cast the complex shape, machine the precision interfaces—delivered both geometric complexity and dimensional accuracy.

Quality verification. Every critical dimension was verified against the client’s specifications using precision measuring equipment. We provided inspection reports with the prototype and production submissions, ensuring their engineering team had data to support design validation and supplier qualification.

The Result

The components moved from prototype approval into stable production without major process changes.

Improved design manufacturability. The DFM review caught potential issues early, resulting in a design that was easier to produce consistently without compromising performance.
Shortened development cycle. By combining in-house mold development, casting, and machining, we eliminated the delays of coordinating multiple suppliers. The client received production-ready parts faster than their original timeline.
Consistent production performance. The validated process held steady across production lots, delivering parts that assembled cleanly and performed reliably in the client’s battery and control systems.

What This Means for Your Project

If you are developing EV battery or electronic control components and need precision aluminum parts that move quickly from prototype to production—without splitting the work across three different suppliers—we can handle the full cycle in-house. From DFM review to CMM-inspected finished parts, we help EV suppliers keep their development programs on schedule.

Have a battery or control system component that needs fast, precise manufacturing? Send us your drawings and we will review the design for manufacturability

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Get in touch with us

Longwin Metal, founded in 2002 as Xiamen Zhenyuan Die Casting Factory, is now an integrated ODM/OEM manufacturer of precision aluminum and zinc die cast components based in Zhangzhou, Fujian.

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Contact: Paul Hu

Phone: +86 13950196086

Email: phu@longwin-metal.com

WhatsApp: +86 13950196086

Address: No. 18-1, Fu Zhao Road, Chen Xiang Town, Chang Tai District, Zhang Zhou City, Fujian Province, China