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ELECTRIC VEHICLE COMPONENT MANUFACTURING
Plastic injection molding is an essential part of the supply chain and manufacturing process for electric vehicle companies. We associate cars with big metal parts and panels rather than plastic.
However, automotive injection molding is a fast-growing part of the EV industry. The exterior of the vehicles is still mostly metal, with some exceptions of carbon fiber, but automotive companies increasingly rely on plastic molded components for internal use.
Tutamen produces Precision Plastic Components for major electric vehicle manufacturers such as Tesla and Arrival. We’re ideally positioned to produce top-quality injection molds for housings, plug casings, internal components, battery boxes, and many more.
The Electric Vehicle Push To Plastics
WHY CHOOSE PLASTIC COMPONENTS FOR EV
REDUCED VEHICLE WEIGHT
AFFORDABILITY
EXCELLENT CHARACTERISTICS
PLASTIC PARTS REDUCE VEHICLE WEIGHT
The main advantage of internal component injection molding is simply that - weight reduction. For electric cars, every bit of weight matters. Weight impacts the travel range any EV can travel between charges—the heavier the vehicle, the more charges it requires.
A longer charge is more attractive to the average driver as it adds convenience and an attractive return on investment. Stringent regulations for vehicle efficiency make plastic injection molding for EV companies a must because it can reduce as much as 30 percent of overall vehicle weight.
PLASTIC PARTS REDUCE VEHICLE WEIGHT
The main advantage of internal component injection molding is simply that - weight reduction. For electric cars, every bit of weight matters. Weight impacts the travel range any EV can travel between charges—the heavier the vehicle, the more charges it requires.
A longer charge is more attractive to the average driver as it adds convenience and an attractive return on investment. Stringent regulations for vehicle efficiency make plastic injection molding for EV companies a must because it can reduce as much as 30 percent of overall vehicle weight.
PLASTIC PARTS REDUCE VEHICLE WEIGHT
The main advantage of internal component injection molding is simply that - weight reduction. For electric cars, every bit of weight matters. Weight impacts the travel range any EV can travel between charges—the heavier the vehicle, the more charges it requires.
A longer charge is more attractive to the average driver as it adds convenience and an attractive return on investment. Stringent regulations for vehicle efficiency make plastic injection molding for EV companies a must because it can reduce as much as 30 percent of overall vehicle weight.
PLASTIC PARTS ARE MORE AFFORDABLE
A significant benefit of working with a plastic manufacturer for automotive thermoplastics is that injection-molded plastic parts are less expensive to produce than their metal counterparts.
Switching from metal parts to plastic components is an effective way to reduce the cost of producing an electronic vehicle.
A reduced manufacturing cost allows car companies to reduce the vehicle’s retail price to make it more attractive in a crowded marketplace.
PLASTIC PARTS HAVE EXCELLENT CHARACTERISTICS
The misconception is that the reduced cost when using plastic components will lead to negative design aspects that impact safety and durability, possibly creating a “cheap” feel. In truth, quality thermoplastics can offer high tensile strength levels, flexibility, impact resistance, heat resistance, and many more positive attributes.
The key is in the supply chain of raw materials and consistently superior quality with no compromises.
These characteristics not only mean that plastic components are just as reliable as metal but also explain why OEMs are using plastic for a versatile array of applications from battery housings to dashboard covers to external panels.
Die Casting For Electric Vehicles
Die casting for the EV industry is similar to injection molded parts because it reduces overall weight. The shift in consumer preference worldwide to electric vehicles has pushed automotive manufacturers to replace heavier components with lightweight, environmentally-friendly counterparts ranging from alloys like Aluminum to Magnesium.
As with plastics, die casting is an effective method to significantly reduce the weight of electric vehicles where battery efficiency is critical. Weight reduction with aluminum and magnesium die-cast components dramatically reduces overall vehicle weight, increasing overall performance.
Tutamen is helping to fuel the evolution by die-casting complex parts with intricate shapes in high volumes within tight tolerances for precision using lightweight alloys.
Aluminum
Automakers who make electric or hybrid cars are increasingly turning to Aluminum due to its combination of excellent mechanical and physical properties and attractive cost reduction.
In addition to weight reduction, high-pressure die-cast aluminum alloys have added dimensional accuracy and stability – not to mention the added strength and high-speed production capabilities.
While Aluminum is lighter than steel, it absorbs more energy, providing an extra layer of safety for the vehicle. While not as light as Magnesium, Aluminum is still 1/3 the weight of steel, which goes a long way to reduce the weight of a vehicle.
That’s why Aluminum die castings are replacing steel in structural and cosmetic body parts (i.e., hoods, doors, bumpers, vehicle bodies, crash boxes, etc.) in modern vehicles.
Aluminum is superb for automotive applications when there’s a need for high visibility and structural integrity. Utilizing aluminum components can help reduce vehicle weight by as much as 40% without compromising the vehicle’s safety.
Magnesium
Magnesium was first used in race cars back in the 1920s to gain an edge over competitors because of how lightweight the material is.
Now automotive manufacturers worldwide use magnesium for applications like airbag casings, steering columns, mirror housings, steering columns, dash encasings, and seat frames.
The renewed interest in high-pressure die casting Magnesium alloys stems from the EV industry’s need for greater battery efficiency. These alloys include AZ91D, with its excellent combination of mechanical properties and the highest strength to weight ratio of any structural metal.
Magnesium is 75% Lighter than Steel, 33% Lighter than Aluminum. Magnesium is 100% recyclable.
Zinc
Although Zinc products are heavier than their Aluminum and Magnesium-based counterparts, they have the highest yield strength of all three alloys.
Zinc can also be cast thinner than any other metal and can hold extremely tight tolerance requirements. While Zinc might not be the best option for a light-weighting strategy, several Zinc-made applications are ideal for EV design and structure.
Tutamen can cast all three families of alloys; Aluminum, Magnesium, and Zinc. Our technical expertise, combined with full-service capabilities and engineering design services, can provide EV manufacturers or part designers with die casting solutions that meet their electric vehicle part design challenges.
OUR CAPABILITIES
Tutamen is an electric vehicle parts manufacturer with manufacturing facilities in China and Mexico. The Tutamen Team is ideally positioned to support the quick-changing pace and speedy output that comes with modern manufacturing. With years of experience, we are the ideal partner to get your product to market quickly, efficiently, and cost-efficiently.
We work closely with our clients to quickly build an inseparable relationship through active communication and the exchange of information. All these combined speeds up the process and goes a long way to cut costs.
