Electric Vehicles Manufacturing
IATF 16949:2016 Certified — Trusted by EV OEMs, Autonomous Driving Startups, and Tier 1 ePowertrain Suppliers — From Early Development Prototypes to Serial Production.
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EV Manufacturing from Validation to Volume
Choose EV-ready process routes, lightweight materials, and reliability-focused finishes for production programs.
CNC Machining
Precision machining for cooling plates, sealing interfaces, and battery pack structural interfaces.
High-Pressure Die Casting
High-volume casting of inverter, motor, and battery housing components with post-machining.
Sheet Metal Fabrication
Fabrication of tray structures, bracketry, and support components for EV chassis platforms.
Trusted by EV OEMs, Autonomous Driving Startups, and Tier 1 ePowertrain Suppliers — From Early Development Prototypes to Serial Production.
CipherFab works with electric vehicle manufacturers, autonomous driving companies, and ePowertrain Tier 1 and Tier 2 suppliers to build infinitely more scalable on-demand supply chains — and get to market faster. CipherFab gives engineering and procurement teams instant access to IATF 16949:2016-certified CNC machining, sheet metal fabrication, high-pressure die casting, injection moulding, tube fabrication, and 3D printing — with DFM review, PPAP documentation, and full material traceability on every programme order.
What We Manufacture
- Battery Pack Enclosures & Structural Trays — Aluminium enclosures and pack trays with IP67/IP68-rated sealing surfaces machined to ±0.005″ and liquid cooling channel integration
- Thermal Management Components — Cooling plates, cold plates, brackets, and housings in aluminium alloys with internal flow channels; leak-tested to VDA 19 cleanliness standards
- Electric Motor Housings & Drivetrain Components — HPDC aluminium housings with post-cast CNC machining of bores, sealing grooves, and bearing seats to tight tolerances
- Onboard Charger & Inverter Enclosures — HPDC aluminium with integrated cooling jackets, EMI surfaces, and CNC-machined O-ring sealing grooves
- Chassis & Structural Components — Lightweight chassis structures combining sheet metal, extrusions, stampings, and welded assemblies
- ADAS & Autonomous Vehicle Components — Sensor housings, brackets, mounts, and connector housings with tight bore tolerances for alignment
- Assembly Tooling & Plant-Floor Fixtures — Fixtures, jigs, and check fixtures for EV production lines
- Rapid Prototyping for EV Development — 3D-printed and CNC-machined prototypes for packaging and thermal validation
Manufacturing Capabilities
- CNC Machining — 3-axis/4-axis/5-axis milling and turning in aluminium 6061/7075/ADC12, stainless 304/316, and engineering plastics; ±0.005″ standard on sealing surfaces and bearing seats; APQP planning and PPAP Level 3 available
- High-Pressure Die Casting (HPDC) — Aluminium, zinc, and magnesium die casting with post-cast CNC machining; IP67/IP69K sealing integrity support; automotive cleanliness per VDA 19
- Sheet Metal Fabrication — Laser cutting, waterjet cutting, press brake bending, and structural welding in aluminium and high-strength steels; friction stir welding (FSW) compatible joint designs
- Tube Fabrication — Laser tube cutting and rotary draw bending in aluminium, stainless, and structural profiles for coolant routing and chassis assemblies
- Injection Moulding — IATF 16949-certified moulding for connector housings, covers, and sub-assemblies with PPAP and production control plans
- 3D Printing — FDM/SLS/MJF for rapid validation; DMLS aluminium AlSi10Mg for metal prototypes with production-representative properties
Quality Assurance
Every EV order on CipherFab includes:
- Certificates of Conformance and material certifications as standard
- Full material and process lot traceability across metallic and polymer components
- CMM inspection and full dimensional reports on request; critical sealing surfaces and bores inspected as standard on HPDC and machined components
- PPAP Level 3 documentation for new programme launches and engineering changes
- APQP planning and control plans for ramp-up to SOP
- SPC monitoring and Cpk reporting on critical-to-quality features
- VDA 19 automotive technical cleanliness compliance for motor and power electronics housings
- DFM review on every uploaded file — wall thickness, draft angles, cooling channel geometry, sealing surface design, and material suitability reviewed before tooling is committed
Certifications & Compliance
- IATF 16949:2016 — Automotive quality management system certification; mandatory standard for EV Tier 1 programme supply
- ISO 9001:2015 — General quality management system across all manufacturing processes
- APQP — Structured programme planning from concept through SOP launch
- PPAP — Level 3 documentation including control plans, dimensional results, and Production Submission Warrant (PSW)
- SPC — In-process monitoring with Cpk reporting on CTQ features; Cpk > 1.33 standard, > 1.67 available for OEM-critical dimensions
- VDA 19 Cleanliness — Automotive technical cleanliness compliance for machined motor housings and battery enclosures
- Material Certifications — Full material traceability and mill certifications on all metallic and polymer components
Why CipherFab for Electric Vehicles
EV programmes run at a pace that exposes every weakness in a traditional supply chain. Battery enclosure designs change after thermal validation. Motor housing tolerances tighten after NVH testing. Chassis structures get lightweighted between prototype and SOP. Every one of these changes demands a manufacturing partner who can respond fast, document everything, and maintain tolerance and quality consistency across programme iterations. CipherFab consolidates HPDC die casting, CNC machining, sheet metal fabrication, tube manufacturing, injection moulding, and 3D printing under one IATF 16949:2016-certified platform and one point of contact — with PPAP, APQP, SPC, and VDA 19 cleanliness support built into every programme order.