Electric vehicles are becoming more and more popular for consumer and commercial drivers, with sales increasing 40% year over year. One of the key outcomes this shift in automotive preferences has caused is an increased demand for precision stamped parts. Stamping processes create light, precise, and virtually identical components for lightweight EV constructions. Learn more about the use of stamping manufacturing in EV components, commonly used materials, and how Keats Manufacturing can play a critical role in your EV production strategies.
Manufacturers have turned to metal stamping manufacturing processes for the production of automotive components for many years. Not only does stamping continue to have a foothold in the production of traditional gas- and diesel-powered vehicles, but stamping can also produce the lightweight, complex components required for electric vehicles. Batteries, for example, require precisely designed and produced parts that can reliably generate the right power levels for optimal vehicle performance. Some of the most critical EV components are produced the precision stamping methods. Stamped components include:
EVs need battery packs made from configurations of smaller individual batteries. Manufacturers use stamping techniques to build enclosures that can safely and securely hold the batteries.
Traditional vehicles often have stainless steel components, which can add extra weight and drag to the vehicle. Electric vehicles benefit from lighter parts, which help increase energy efficiency, and manufacturers can use stamping to create lightweight aluminum parts.
The manufacturing process itself can be more energy-efficient for electric vehicles, as the tooling requirements for aluminum parts are less energy-intensive. Even more complex stamped goods can be produced with a greater focus on energy-efficient components, machines, and assemblies.
EVs feature busbars that transmit current from the vehicle’s battery pack to different electrical configurations and subassemblies. These subassemblies and separate applications include the car’s engine, communications systems, windows, sunroofs, anti-lock brakes, remote controls, and sensors. The busbars themselves and the individual assemblies are precision manufactured with stamping processes. Some of the most commonly stamped components for EVs include:
- Custom-sized and designed busbars
- Lead frames
- Lighting components
- Transmission lead frames
Each component and assembly is produced with metals and alloys that give the product the appropriate weight, conductivity, and longevity characteristics. At Keats Manufacturing, we develop stamped goods built for high-voltage applications like electric vehicles. The metals we work with include:
- Beryllium copper
- Phosphor bronze
- Carbon steel
- Galvanized steel
- Stainless steel
Contact us today to learn more about the materials we can use for EV charging systems, sub-assemblies, and other automotive components.
At Keats Manufacturing, we provide our clients with complete metal stamping services. Our experienced technicians are dedicated to providing a high level of product excellence for every part, no matter how simple or complex. Every component is built for years of reliable performance in outdoor and extreme conditions, user comfort, and safety. We offer industry expertise and actionable manufacturing solutions for the production of electric components and car parts.
Turn to Keats Manufacturing Co. for metal stamping, manufacturing, wire form design, and more. Our company is ISO 9001, ISO 14001, and TS 16949 compliant. We use CAD/CAM software to facilitate the design and fabrication of cutting-edge EV component designs, and we employ 25 top-tier die makers to guide the production of long-lasting dies and tools for our stamping processes. We produce standard and custom metal stamped components. Contact us today to learn more about our electric vehicle manufacturing capabilities or request a quote to start your order.