EV Battery Pack Aluminum Enclosure Frame
We engineer and manufacture high-precision, custom aluminum enclosure frames for Electric Vehicle (EV) battery packs. Supporting Cell-to-Pack (CTP) and modular architectures, our engineering team provides end-to-end contract manufacturing--from heavy extruded structural sections to 5-axis CNC machining, Friction Stir Welding (FSW), and automated leak testing.
- Product Introduction
We engineer and manufacture high-precision, custom aluminum enclosure frames for Electric Vehicle (EV) battery packs. Supporting Cell-to-Pack (CTP) and modular architectures, our engineering team provides end-to-end contract manufacturing--from heavy extruded structural sections to 5-axis CNC machining, Friction Stir Welding (FSW), and automated leak testing.
Technical Specifications and Manufacturing Capabilities
|
Parameter |
Specification and Capability |
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Quality Certifications |
IATF 16949:2016, ISO 9001:2015, ISO 14001 |
|
Material Options |
Extruded 6061-T6, 6063-T6, 6005A-T6, Cast A356-T6 |
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CNC Machining Accuracy |
Profile tolerances up to +/- 0.02 mm; Hole pitch accuracy within +/- 0.015 mm |
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Max Machining Envelope |
5-Axis CNC Milling up to 3500 mm x 2200 mm x 800 mm |
|
Joining Technologies |
Friction Stir Welding (FSW), Robotic CMT/MIG Welding, Structural Adhesive Bonding |
|
Sealing and Protection |
Helium Leak Mass Spectrometry Testing; Guarantees IP67 / IP68 Enclosure Integrity |
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Surface Treatment |
Hard Anodizing (Class 2), E-Coating, Powder Coating, Chromate Conversion |
Structural and Thermal Management Integration
Modern battery tray structures require seamless structural stability and thermal protection. Our engineering team integrates these sub-systems directly into the frame manufacturing process:
CTP Frame Design: Optimized internal beam configurations providing crash-structure energy absorption without unnecessary dead weight.
Liquid Cooling Tray Integration: Friction Stir Welding (FSW) joins cooling plates directly to structural profiles, eliminating leak paths and maintaining thermal contact resistance below 0.05 K*cm^2/W.
Post-Joining CNC Finishing: To eliminate heat distortion from joining, we perform critical face-milling and precision hole-drilling after welding to guarantee structural flatness across 2.5 m+ frames.
Case Study: Distortion Control for Large Commercial EV Frames
A European Tier-1 commercial vehicle supplier required a 2200 mm x 1400 mm aluminum battery enclosure. Thermal distortion during traditional MIG welding was causing an out-of-flatness exceeding 2.8 mm, preventing IP67 seal compression.
We redesigned the joining process using Friction Stir Welding (FSW) paired with custom hydraulic clamping fixtures, followed by post-joining 5-axis CNC machining on key mounting points.
Overall frame flatness was held within 0.4 mm, passing 100% Helium Leak Testing at 10^-5 mbar*L/s with zero scrap during mass production.
Quality Assurance and Process Control
Every production batch passes strict automotive quality gates before dispatch:
Incoming Material Validation：100% Batch Traceability. Spectrometric chemical analysis, tensile strength testing, and ultrasonic flaw detection on raw extruded 6xxx profiles.
In-Process Distortion Control：FSW and Automated Clamping. Controlled heat-input welding using automated fixtures to limit thermal deviation.
Full CMM Inspection：3D Dimensional Verification. Key mounting holes, sealing faces, and locating pins measured on Zeiss CMM (2500 mm x 1500 mm table).
100% Hermetic Leak Testing：IP68 Quality Gate. Helium mass spectrometry and air differential pressure testing on integrated cooling channels and gasket seals.
FAQ
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