Scaling Die-Cast Housing Production for an EV Battery Component Line
An EV component manufacturer needed to scale battery housing production from prototype volumes to several thousand units a month without a quality dip.
The challenge
An EV component manufacturer had validated a battery housing design at prototype volumes but needed a partner who could scale to several thousand units a month while holding thermal-management tolerances that prototype tooling hadn't been tested against.
What we did
We built production-intent die-cast tooling with cooling channel positions optimised specifically for the housing's wall-thickness variation, and ran a 500-unit soft-launch batch through full dimensional and leak testing before committing to the production schedule.
4,200
Units/month at steady state
100%
Leak-test pass rate on soft launch
3
Design iterations before tool cut
The housing is now in its second production year with no tooling rework, and the soft-launch process has since become our standard approach for any new EV component program.
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