Batteries are at the heart of different types of NEV powertrains. Battery management systems with inverters translate power smoothly and safely, whereas the cooling of battery housings and inverter housings is critical. Manufacturing of these crucial elements requires precise molds for the production of housings and castings.

Automotive electrical architecture is moving from flat to domain-controlled modules and high-level zonal control modules. This implies implementing several autonomous levels and reducing lag in communications. As a consequence, the number of micro control units (MCU) and zonal electronic control units (ECU) increase. Supply chains must support this migration and the production volumes that are involved.

Hydrogen powertrain is a mobility solution that is gradually gaining momentum, backed by governmental subsidies. Producing power from hydrogen and oxygen supplied into it, stacks are made of thinly stamped or embossed metal alloy sheets with thickeness ranging from 0.04 mm to 0.12 mm. Typically, producing bipolar plates for hydrogen powertrain require mold tooling and dies with variation less than 5 μm.

Castings for the drivetrains of hydrid energy, battery-powered and fuel cell energy vehicle are key to ensure smooth transition of power with the lowest noise and the highest durability. These castings require self-cooling designs while presenting unique shapes and deep cavities. Creating mold for these castings is a complicated task and requires many toolings.

EV motors are coupled with different types of hybrid energy vehicle and battery-powered vehicle powertrains. The stamped lamination sheet thickness typically ranges from 0.15 mm to 0.3 mm. A wide range of designs with sharp corners and unique profiles to boost efficiency make it that manufacturing of such parts  challenging for mold makers. Today most designs use smaller thickness to reduce stamping machine load thereby reducing power consumption, which raises the need for high-precision molds.