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Battery Casings CNC Machining Services for the Automotive Industry
From module housings and pack enclosures to cooling plates and cell retention frames, battery housings are custom-machined protective enclosures that offer structural integrity and crash protection, thermal management, and environmental sealing for lithium-ion battery packs deployed in electric and hybrid vehicles. Zintilon specializes in the CNC machining of battery trays, thermal interface plates, module end plates, and sealing covers for critical automotive energy storage and battery protection applications where exceptional dimensional accuracy, thermal conductivity, and long-term reliability are paramount.
- Machining for precise sealing surfaces and thermal pathways
- Tight tolerances up to ±0.0003 in for crash safety compliance
- Precision milling, forming, welding & thermal optimization
- Support for rapid prototyping and full-scale production
- ISO 9001-certified manufacturing with automotive industry expertise
Trusted by 15,000+ businesses
Automotive Connectors Parts Machining Capabilities
Fast Delivery
A professional engineering team that can respond quickly to customer needs and provide one-stop services from design to production in a short period of time to ensure fast delivery.
High Precision
We are equipped with automated equipment and sophisticated measuring tools to achieve high accuracy and consistency, ensuring that every part meets the most stringent quality standards.
ITAF16949 Certified
As a IATF16949 certified precision manufacturer, our products and services have met the most stringent quality standards in the automotive industry.
From Prototyping to Mass Production
Zintilon is certified for the ISO 9001 standard and supplies engineered components to automotive manufacturers, battery system suppliers, EV pack assemblers, and energy storage system integrators worldwide.
Prototype Battery Casings
Obtain high-precision prototypes of battery casing assemblies that accurately replicate your final design. Verify structural rigidity, evaluate thermal performance, test sealing integrity, and confirm crash protection before full-scale automotive production.
Key Points:
Key Points:
- Rapid prototyping with high precision
- Tight tolerances (±0.0003 in)
- Test structural strength, thermal management, and sealing early
EVT – Engineering Validation Test
Battery casing configuration and design must meet all dimensional accuracy, structural strength, and thermal management requirements for prototype construction. Identify thermal hotspots and sealing failures early to ensure safe battery operation, as prototype casings are adjusted for cooling and crash protection requirements.
Key Points:
Key Points:
- Validate prototype functionality
- Rapid design iterations
- Ensure readiness for production
DVT – Design Validation Test
Use different materials and cooling designs to analyze battery casing performance for thermal stability and crash absorption. This is to assess the automotive battery system performance to achieve desired safety ratings and thermal control before production.
Key Points:
Key Points:
- Confirm design integrity and safety specifications
- Test multiple materials and configurations
- Ensure production-ready performance
PVT – Production Validation Test
Assess large-scale production capabilities for battery casings and evaluate production consistency challenges before initiating full production to address uniformity and efficiency gaps in the manufacturing process flow.
Key Points:
Key Points:
- Test the large-scale production capability
- Detect and fix process issues early
- Ensure consistent part quality
Mass Production
Efficiently manufacture high-quality, crash-safe battery casings, guaranteeing dependable automotive energy storage protection and punctual delivery to vehicle manufacturers and battery system suppliers.
Key Points:
Key Points:
- Consistent, high-volume production
- Precision machining for automotive quality
- Fast turnaround with strict quality control
Simplified Sourcing for
the Automotive Industry
Through excellent processing technologies such as CNC machining, sheet metal manufacturing, metal casting, etc., we can achieve a balance between quality and speed, whether it is special-shaped parts, lightweight or cost effect.
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Automotive Industry, Battery Casings, Machining Capabilities
We are equipped with CNC multi-axis machining centers and large-format fabrication systems to ensure quality while taking advantage of our experienced machining to deliver Battery Casings CNC Machining Services for the Automotive Industry. Each part, from battery pack trays with integrated cooling channels to module housings with cell retention features, thermal interface plates with microchannel heat exchangers, and high-voltage connector mounting plates with electrical isolation, is precisely designed for maximum energy density and to minimize thermal gradients with dependable performance for over 10 years or 300,000 km.
We perform precision CNC milling for casing bodies with dimensional accuracy of ±0.100 mm, precision drilling for mounting holes with positional accuracy of ±0.075 mm, router cutting for cooling plate profiles with channel width accuracy of ±0.150 mm, and forming operations for structural ribbing with angle accuracy of ±1 degree. We also conduct leak testing and crash simulation validation. We manufacture battery casings from aluminum alloys (5083, 6061-T6, AlSi10Mg) for excellent thermal conductivity at 150-200 W/m·K and corrosion resistance, steel sheet (SPCC, DP590, DP780) with protective coatings for crash energy absorption and cost-effectiveness, composite materials (carbon fiber, glass fiber reinforced polymers) for lightweight construction reducing mass by 30 to 50 percent, or specialized materials like extruded aluminum for cooling plates with integrated flow channels, stainless steel 304/316 for marine and high-corrosion environments, and flame-retardant polymers for electrical isolation and thermal barriers. We ensure excellent structural integrity with crash loads supporting forces from 50 to 200 kN per FMVSS 305, superior thermal management with heat dissipation capacity from 5 to 50 kW, continuous operation at temperatures from -40°C to 60°C, and mechanical durability for over 10 years or 300,000 km of service life.
We perform precision CNC milling for casing bodies with dimensional accuracy of ±0.100 mm, precision drilling for mounting holes with positional accuracy of ±0.075 mm, router cutting for cooling plate profiles with channel width accuracy of ±0.150 mm, and forming operations for structural ribbing with angle accuracy of ±1 degree. We also conduct leak testing and crash simulation validation. We manufacture battery casings from aluminum alloys (5083, 6061-T6, AlSi10Mg) for excellent thermal conductivity at 150-200 W/m·K and corrosion resistance, steel sheet (SPCC, DP590, DP780) with protective coatings for crash energy absorption and cost-effectiveness, composite materials (carbon fiber, glass fiber reinforced polymers) for lightweight construction reducing mass by 30 to 50 percent, or specialized materials like extruded aluminum for cooling plates with integrated flow channels, stainless steel 304/316 for marine and high-corrosion environments, and flame-retardant polymers for electrical isolation and thermal barriers. We ensure excellent structural integrity with crash loads supporting forces from 50 to 200 kN per FMVSS 305, superior thermal management with heat dissipation capacity from 5 to 50 kW, continuous operation at temperatures from -40°C to 60°C, and mechanical durability for over 10 years or 300,000 km of service life.
Aerospace
Materials & Finishes
Materials
We provide a wide range of materials, including metals, plastics, and composites.
Finishes
We offer superior surface finishes that enhance part durability and aesthetics for applications requiring smooth or textured surfaces.
Specialist Industries
you are welcome to emphasize it in the drawings or communicate with the sales.
Materials for Battery Casings
Our CNC machine shop uses and offers for battery casings 12+ lightweight alloys, high-strength steels, and thermal management materials to support rapid prototyping, precision automotive manufacturing, and to manufacture and maintain quality to SAE, UN ECE R100, and automotive battery safety specifications.
High machinability and ductility. Aluminum alloys have good strength-to-weight ratio, high thermal and electrical conductivity, low density and natural corrosion resistance.
Price
$ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.003 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Steel is a strong, versatile, and durable alloy of iron and carbon. Steel is strong and durable. High tensile strength, corrosion resistance heat and fire resistance, easily molded and formed. Its applications range from construction materials and structural components to automotive and aerospace components.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.001 mm (routing)
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Stainless steel alloys have high strength, ductility, wear and corrosion resistance. They can be easily welded, machined and polished. The hardness and the cost of stainless steel is higher than that of aluminum alloy.
Price
$ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Titanium is an advanced material with excellent corrosion resistance, biocompatibility, and strength-to-weight characteristics. This unique range of properties makes it an ideal choice for many of the engineering challenges faced by the medical, energy, chemical processing, and aerospace industries.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Highly resistant to seawater corrosion. The material’s mechanical properties are inferior to many other machinable metals, making it best for low-stress components produced by CNC machining.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Brass is mechanically stronger and lower-friction metal properties make CNC machining brass ideal for mechanical applications that also require corrosion resistance such as those encountered in the marine industry.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Few metals have the electric conductivity that copper has when it comes to CNC milling materials. The material’s high corrosion resistance aids in preventing rust, and its thermal conductivity features facilitate CNC machining shaping.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Iron is an indispensable metal in the industrial sector. Iron is alloyed with a small amount of carbon – steel, which is not easily demagnetized after magnetization and is an excellent hard magnetic material, as well as an important industrial material, and is also used as the main raw material for artificial magnetism.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Due to the low mechanical strength of pure magnesium, magnesium alloys are mainly used. Magnesium alloy has low density but high strength and good rigidity. Good toughness and strong shock absorption. Low heat capacity, fast solidification speed, and good die-casting performance.
Price
$ $ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Let’s Build Something Great, Together
FAQs: Battery Casings for Automotive Industry Applications
Battery casings encompass precisely machined pack enclosures ranging from 1000 x 800 mm to 2000 x 1500 mm, safeguarding battery capacities from 40 to 100+ kWh, module housings incorporating 12 to 24 cells at a thermal interface flatness of ±0.100 mm, cooling plates featuring microchannels with widths ranging from 2 to 8 mm dispersing coolant flow rates from 5 to 30 liters per minute, cell retention frames controlling cell spacing within ±0.200 mm, high-voltage covers with sealing protection to IP67 under IEC 60529, and crash protection system with energy absorption capabilities of 10 to 50 kJ. These components require sealing surfaces flatness of ±0.050 mm, mounting hole positional accuracy of ±0.100 mm, thermal range of -40°C to 60°C, pressure boundary to 300 kPa for a liquid cooling system, and crash safety regulations, FMVSS 305 and UN ECE R100.
Aluminum alloys (5083, 6061-T6, AlSi10Mg) demonstrate extraordinary thermal conductivity (150 – 200 W/m·K) allowing heat removal enabling cell temperature uniformity within ± 5°C, low weight (2.7g/cm³) extends vehicle range due to 20 to 40 percent reduction of battery system weight, superior corrosion resistance in severe automotive environments, complex geometries with integrated cooling channels, advance formability, and recyclability supporting sustainability goals. High-strength steel (DP590, DP780) with yield strength 590-780 MPa has outstanding crash energy absorption, protecting cells in case of side impact and bottom strike. In addition to automotive proven durability, it is also cost-effective for large format pack enclosures and has good weldability for structural assembly. Composite materials contribute to ultra-lightweight construction, achieving a 30 to 50 percent reduction of casing weight. They also exhibit a high specific strength-to-weight ratio, prevent short circuits due to excellent isolation, and allow design flexibility for integrated thermal barriers and mounting features.
Multi-axis CNC milling creates complex casing geometries with dimensional accuracy of ±0.100 mm. Precision drilling generates mounting and drainage holes with a diameter tolerance of ±0.050 mm and positional accuracy of ±0.075 mm. CNC routing cuts cooling plate profiles from aluminum sheets with channel width accuracy of ±0.150 mm. Face milling produces sealing surfaces and module mounting areas with flatness of ±0.050 mm. Forming and bending create structural ribs and mounting flanges with an angle accuracy of ±1 degree. Friction stir welding joins aluminum components with weld strength exceeding 85 percent of the base material. Laser cutting creates intricate vent patterns and cable routing openings with edge accuracy of ±0.100 mm. Surface treatment includes anodizing, powder coating, or e-coating for corrosion protection per SAE J2334, achieving 1000+ hours salt spray resistance.
We can preserve the +/- 0.050 mm flatness of sealing surfaces for gaskets and O-ring interfaces while obtaining IP67 protection to IEC 60529, achieving +/- 0.100 mm hole positional accuracy for module and pack assembly alignment, maintaining the cooling channel width to +/- 0.150 mm to guarantee consistent coolant distribution, preserving the thermal interface flatness to +/- 0.100 mm for cell to plate contact with thermal resistance of 1.0 °C·cm²/W, overall part deviations of +/- 0.200 mm, the mounting surfaces parallel to each other within +/- 0.100 mm and edge deviations of within +/- 0.300 mm for every 500 mm are respected. These tolerances maintain structural integrity which withstands crash loads according to FMVSS 305 and UN ECE R100, thermal regulation which retains the cell temperature variation to +/- 5 °C and moisture loss to below 1 g/hour, sealing integrity of IP67, pressure drop containing to 300 kPa for liquid cooling, and a useful life of more than 10 years or 300,000 km with minor degradation, all while sustaining lower than 5 °C thermal variation across the pack.
Yes, we perform rapid prototyping with CMM dimensional inspection at ±0.010 mm accuracy, flatness measurement using precision straightedges and laser scanning, leak testing with helium mass spectrometry detecting rates of 1×10⁻⁵ mbar·L/s, pressure testing to 450 kPa (1.5x operating pressure), thermal cycling from -40°C to 80°C for 100 cycles, crash simulation validation using FEA, and IP rating verification per IEC 60529. We conduct low-volume production for performance EVs and specialty applications, producing 50 to 2,000 casings annually, and high-volume production for automotive OEMs. We supply vehicle manufacturers with battery casing components in volumes from thousands to hundreds of thousands annually, including dimensional certification with flatness and positional accuracy documentation, leak testing reports with seal integrity verification, material certification with thermal conductivity and strength data, pressure test documentation for cooling system integrity, IP rating certification per IEC 60529, crash safety compliance documentation per FMVSS 305 and UN ECE R100, corrosion resistance validation per SAE J2334, and full quality documentation meeting IATF 16949, ISO 9001, SAE J2464, UN ECE R100, and automotive battery system manufacturing and safety standards.
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