定制金属冲压服务是电动汽车电池热管理部件高精度制造的关键支撑。 LS Manufacturing的金属冲压服务可以将热管理部件的公差固定在0.015mm，这将解决冷板冲压的问题，降低买家的量产风险。随着电动汽车电池能量密度的不断提高，散热部件的精度将直接影响电池组的寿命和安全性。
甚至很多（潜在）客户都会遇到一些困难，例如冷板冲压出现各种凹凸不平、管道泄漏、高导热材料冲压出现裂纹等。传统上保持0的平整度几乎是不可能的。02mm和高批量制造成本和二手数据会给决策带来偏差。在本文中，我们将讨论 LS Manufacturing 如何通过使用多物理场仿真和高精度级进模方法，为您提供与电池冷却系统设计相关的尺寸漂移问题的解决方案，以改进您的卧式逻辑并降低批量生产风险。
通过专业的精密冲压服务，客户可以持续节省成本，从而实现更好的项目财务业绩。 We offer free cost calculations for your project after you share your production volume and part parameters to create a customized stamping solution that fits your budget.
Figure 3: Multiple metallic cooling plate parts arranged on a large industrial fixture.
What Technical Factors Impact The Lead-Time Of Custom Battery Stamping Parts For Prototype Testing?
The successful launch of the custom battery stamping parts project depends on the essential prototype development cycle. LS Manufacturing uses modular die sets which allow the company to produce its initial T1 prototypes within 10 to 15 working days. This approach leads to a development time reduction that exceeds 40 percent compared to the industry standard which requires 25 days for development.
Switching Logic Between Soft and Hard Molds
The development cycle can be shortened and expenses can be lowered through the use of soft and hard mold switching during the prototype verification phase. We create adaptable switching strategies that align with the client's project timeline while utilizing long-tail keywords related to prototype stamping lead time.
Initial Verification: T1 prototypes use soft tooling to achieve delivery within 10 to 15 working days for initial performance evaluation.
Optimization and Adjustment: The test results enable immediate changes to soft tooling parameters which lead to T2 prototypes being delivered within 2 to 3 working days.
Mass Production Transition: The development of hard tooling for mass production begins after the successful verification process which takes four weeks to complete.
Prototype preparation requires a combination of fast execution and accurate results because laser cutting technology enables better processing results for intricate designs.
Preparation Process of Complex 3D Shape Prototypes
The five-axis laser cutting system together with a basic stamping die enables us to create prototypes for custom battery stamping parts which require complex 3D shapes without needing to wait until entire mold systems are finished.
The specific process is as follows:
Five-axis laser cutting is used to create the part prototype.
The prototype is then shaped using a simple stamping die.
The final step involves high-precision grinding which guarantees that the sample meets required dimensional accuracy standards.
The entire process takes only 12-15 working days, significantly shortening the project launch time.
How Does LS Manufacturing Ensure 100% Airtightness In Stamped EV Thermal Management Assemblies?
The complete testing process requires online helium leak detection and advanced edge bending methods to verify that all stamped components maintain bubble-free conditions when exposed to 2.5 bar pressure and 10⁻⁶ mbar·l/s leak rate restriction which meets ISO 26262:2018 ASIL D safety requirements.
Relationship between Bending Radius and Sealing Surface Deformation
The size of the bending radius (R angle) directly affects the compressive permanent deformation of the sealing surface. A small R angle will lead to uneven stress on the sealing surface, which easily forms gaps while a large R angle will create problems during assembly.
Our testing showed that a radius (R) of 0.8-1.2mm gives the sealing surface its smallest compression set and its best leakage protection. The principle of thermal assembly airtightness, which we defined as "thermal assembly airtightness," guarantees that the thermal components metal stamping process achieves complete airtightness and metal bending precision enhances the sealing performance.
Real-time Rejection of Defective Products
Our facility includes an automated image recognition system that identifies burr heights on the edges of stamped components throughout the entire production process. The system will reject defective products when burr heights reach 0.03mm while simultaneously generating an alarm which guarantees that all products meet compliance requirements for shipment. The components enable battery pack assembly without leakage risks, so customers can use them directly while minimizing their future rework expenses.
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Strict airtightness testing and defective product rejection processes provide a solid guarantee for the safety of customers' battery packs. If you need to ensure 100% airtightness of stamped components, please contact our engineers for detailed testing procedures and a free airtightness testing standard manual.
Case Study: LS Manufacturing Customized Aluminum 3003 Cooling Plates For a Leading European EV Battery Pack Brand
The case study examines a top European electric vehicle battery company which develops and makes premium electric vehicle batteries. The brand needs 200,000 aluminum alloy 3003 cold-rolled plates each year to produce battery thermal management systems for its premium electric vehicles.
Client Challenges:
The client experienced a critical leakage problem during mass production which resulted in 5% leakage after the cold-rolled plates underwent brazing. The process resulted in extensive rework which increased production costs and extended vehicle delivery times thus damaging the brand's reputation.
LS Manufacturing Solution
The engineering team began an immediate site assessment of the client's production plant after receiving their request. The root cause of the problem occurred when the original supplier provided materials that exceeded 0.1mm flatness tolerance limits which caused poor adhesion between the brazed surfaces that led to leakage problems. Our project experience demonstrates that high flatness tolerances create irregular solder patterns during brazing which produces micro gaps that lead to leakage.
To solve this problem, our team created a unique metal stamping service which meets the specific requirements of our client.
The process involved the creation of high-precision continuous stamping dies which use an inductive pressure monitoring system to deliver real-time pressure information during stamping operations.
The process required us to establish a stamping speed of 45 spm which we achieved through the implementation of a Teflon-coated die core system that minimized material contact friction.
We implemented an online helium leak detection system which used Shanghai institute of quality supervision and inspection technology helium leak detection standards to test product airtightness. The system achieved leakage control at 10⁻⁶ mbar·l/s level through its leak detection testing process.
Results and Value:
The implementation process resulted in the client's cold-rolled steel sheet flatness variation reaching ±0.02mm. The brazing pass rate (FPY) increased from 95% to 99.8%. The thermal management system costs per pack decreased by $300, which resulted in total annual maintenance savings of $6 million. The process improvements which we made to our nesting technology system enabled us to achieve 82% material usage, which provided our clients with additional savings on materials.
Stamping tolerance control ensures long-term stable product precision. The company has supplied this client with more than 300,000 cold-rolled steel sheets which achieved a product qualification rate above 99.8%. This achievement received positive feedback from the customer.
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If you are also facing issues such as high brazing leakage rates and large flatness deviations in cold-rolled steel sheets, please review the complete technical details of this case study. Contact our engineers for a free DFM assessment tailored to your project and a customized stamping solution to help you reduce production costs and enhance product competitiveness.
常见问题解答
Q1: What is the least tolerance level for aluminum alloy battery cold-rolled steel sheets using LS manufacturing?
LS Manufacturing is able to realize stable large batch production of composite aluminum alloy battery cold-rolled steel sheets by utilizing high-precision grinding die and online monitoring system.Tolerance control is capable of within 0.015mm accurately which would satisfy the high-precision production standard of automotive grade.
Q2: Do you agree with shifting to large scale production by moving from pre-products to prototypes?
We support toward Series Production through development from prototype to series production. We will provide quick prototype service in the soft mold, for product verification. After that, the development and conversion to large-scale progressive die are capable to be carried out in 4 weeks.
Q3: How do you improve the cracking problem at high thermal conductivity aluminum 3003?
Through finite element simulation technology, we change the drawing ratio to predict cracking danger accurately, at the same time, we incorporate localized annealing & segmented drawing process into certain work stations to positively get rid of in-wall material stress, clear up the stamping cracking of 3003 aluminum once and for all.
Q4: Can you provide test reports that comply with IATF 16949 standards?
LS Manufacturing provides complete PPAP Level 3 documentation for each batch of products, including material certification, dimensional reports, and CPK records, fully compliant with IATF 16949 standards and meeting the certification requirements of Tier-1 suppliers.
Q5: What is the average cost of custom stamping dies?
The cost of custom stamping dies depends on the complexity of the part and its lifespan requirements, typically ranging from $3,000 to $30,000. We can reduce die wear through optimized layout techniques, helping customers quickly recoup their die investment costs.
Q6: How do you make sure the cleanliness of the surface of a part by stumping for ensuring subsequent welding?
We have been using the totally automated ultrasonic cleaning line for this kind of job. It tightly controls the residual grease on the surface of the stamped parts to below 2mg/m². It totally complies with the very harsh requirement of follow-up brazing operations to avoid any incomplete or missed welds.
Q7: Do they accept small batch customized orders?
For new startup EV projects, we accept trial production with MOQs starting at just 500 pcs.We have a special small-batch production line build from directly working with customers from the idea research and development stage to the final marketing of their product, including providing support through the entire technical process.
Q8: What is the way to do instant quotes?
Simply upload yourpart drawings in the STEP/DWG format, and in less than 24hours our engineers will analyze the drawing and send you a quote including insight in the design for manufacturing (DFM), manufacturing costsand delivery time.
摘要
In the intense competition of EV market, the accuracy of thermal management components is not only a technical parameter but also a mainstem of brand reputation. Select the right custom metal stamping supplier to accomplish the all balancing between the longevity, safety, and cost of the battery pack, you can always trust LS Manufacturing.
With more than a decade practical experience, accurate technical solutions, and reliable end-to-end services, we successfully to resolve every customer's stamping challenge, and help EV projects to achieve the go-to-market as soon as possible.
Please do not accept poor stamping quality as the failure point of your pack design.
Call the senior engineers at LS Manufacturing for a free DFM (Design for Manufacturability) review of your project. Simply upload your STEP/DWG drawings or email our Technical Department. In 24 hours we will provide you with a tailored EV stamping service solution which meets your project needs for both performance and ROI, paving the way for fast Mass Production of your EV and Market capture.
The contents of this page are for informational purposes only. LS Manufacturing services There are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information.不应推断第三方供应商或制造商将通过 LS Manufacturing 网络提供性能参数、几何公差、具体设计特征、材料质量和类型或工艺。 It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS 制造团队
LS Manufacturing 是一家行业领先的公司。专注于定制制造解决方案。 We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services. Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified.我们为全球150多个国家的客户提供快速、高效、高质量的制造解决方案。无论是小批量生产还是大规模定制，我们都能以最快的24小时内交货满足您的需求。选择LS制造。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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