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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Electric Vehicles Manufacturing from Prototype to Production for New Product Development
CipherFab's Digital Manufacturing platform has an endless combination of processes, finishes, and materials.
CNC Machining
3-axis, 4-axis, and 5-axis milling and turning in aluminium 6061/7075/ADC12, stainless 304/316, and engineering plastics; tolerances to ±0.005″ standard on battery enclosure sealing surfaces, motor bore diameters, and bearing seats; APQP planning and PPAP Level 3 documentation available
High-Pressure Die Casting (HPDC)
Aluminium, zinc, and magnesium alloy die casting at 10,000–20,000 psi injection pressure; wall thickness from 0.08″; post-cast CNC machining of critical dimensional features; automotive cleanliness per VDA 19; IP67/IP69K sealing surface integrity
Sheet Metal Fabrication
Laser cutting, waterjet cutting, press brake bending, and structural welding in aluminium and high-strength steel for battery trays, chassis structures, and enclosure panels; flat tolerances to ±0.005″; friction stir welding (FSW) compatible joint designs
Tube Fabrication
Laser tube cutting and rotary draw bending in aluminium, stainless, and structural steel profiles for coolant routing, structural frames, and chassis assemblies
Injection Moulding
IATF 16949-certified moulding for connector housings, covers, and device sub-assemblies in ABS/PC, PA-GF, PP, PEEK, and flame-retardant engineering resins; full PPAP documentation and production control plans
3D Printing
FDM, SLS, and MJF for rapid prototype validation of battery module layouts, housing packaging, and thermal management geometries; DMLS in aluminium AlSi10Mg for metal prototypes requiring production-representative thermal and structural properties
IATF 16949:2016 Certified — 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 scalable on-demand supply chains and get to market faster. Our IATF 16949:2016-certified platform gives engineering and procurement teams instant access to CNC machining, HPDC die casting, sheet metal fabrication, tube manufacturing, injection moulding, and 3D printing — with PPAP documentation, DFM review, and full material traceability on every programme order.
What We Manufacture
- Battery Pack Enclosures & Structural Trays Aluminium battery enclosures, pack trays, and structural housings — fabricated from extruded aluminium profiles, sheet metal, and HPDC castings; IP67/IP68-rated sealing surfaces machined to ±0.005″; liquid coolin
- Thermal Management Components Liquid cooling plates, cold plates, thermal interface brackets, and heat exchanger housings
- Electric Motor Housings & Drivetrain Components Motor housings, stator carriers, gearbox housings, differential cases, and reduction gear covers
- Onboard Charger & Inverter Enclosures Motor controller housings, onboard charger (OBC) enclosures, and power electronics housings
- Chassis & Structural Components Battery-integrated structural floor frames, chassis rails, cross-members, and mounting brackets
- ADAS & Autonomous Vehicle Components LiDAR housings, radar sensor brackets, camera mounts, and connector housings
- Assembly Tooling & Plant-Floor Fixtures Custom assembly fixtures, alignment jigs, check fixtures, and manufacturing aids for EV production lines
- Rapid Prototyping for EV Development 3D-printed and CNC-machined prototypes for battery module designs, drivetrain packaging studies, and thermal management validation
Quality Assurance
Every EV order on CipherFab includes:
- Certificates of Conformance and material certifications as standard
- Full material and process lot traceability across all metallic and polymer components
- CMM inspection and full dimensional reports on request; critical sealing surfaces and bore diameters 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 structured programme 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
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. Whether you are sourcing battery enclosure prototypes, scaling motor housing production, or managing a complex multi-process ePowertrain BOM from development to SOP launch, CipherFab gives your programme team the precision, compliance documentation, and supply chain agility your EV schedule demands.
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