Industry
Electric
Mobility.
Lightweight aluminium castings for EV drivetrains, power electronics, and battery systems. A380 alloy in thin-wall HPDC for the strength-to-weight ratio EV applications demand. Engineering support for new programme DFM at the design stage.
Sector Overview
Electric Mobility
Electric vehicle drivetrains and power electronics create demand for castings that are simultaneously lightweight, thermally managed, dimensionally precise, and producible at scale. Aluminium is the default material: it offers one-third the density of steel, adequate thermal conductivity for passive cooling in many housings, and the dimensional repeatability of HPDC for high-volume production.
A380 alloy is preferred for EV applications requiring thin walls and higher mechanical properties than ADC12. Its better fluidity in HPDC allows wall thicknesses of 1.5 mm or less — important for motor housings and inverter enclosures where every gram of unnecessary mass affects range. SAPL's 5-machine HPDC line covers 180T to 450T clamping force, suitable for EV components in the 0.2 kg to 8 kg range.
EV programmes typically involve significant DFM iteration before tooling is committed. SAPL's engineering support capability — DFM analysis, mould flow simulation, and prototype sampling — is designed to front-load this iteration before the tooling budget is spent, reducing the number of T1/T2 die correction cycles.
What OEMs Require
Understanding your requirements
These are the recurring requirements SAPL sees from OEMs and procurement teams in this sector — and how our process and quality system addresses them.
Thin-wall capability in A380
EV components require wall thicknesses of 1.5–2.5 mm in many areas. A380's high fluidity and HPDC's injection pressure enable consistent fill of thin sections. Mould flow simulation confirms fill pattern before tooling is cut.
Weight optimisation
Every gram matters in EV applications. DFM review includes wall thickness analysis to confirm the minimum section required for structural integrity — removing weight that isn't doing useful work.
Thermal management geometry
Motor housings and inverter enclosures frequently include cooling channels or fin geometry that must be cast accurately. SAPL reviews cooling geometry during DFM to confirm castability before tooling.
Early-stage engineering involvement
EV programmes move fast. SAPL's DFM analysis and mould flow simulation service can be engaged during design — before drawings are frozen — to prevent tooling rework driven by manufacturability issues discovered late.
Capabilities
Processes that serve this sector
These capabilities are most relevant to Electric Mobility component programmes.
High Pressure Die Casting
Five fully-automatic HPDC machines from 180T to 450T.
Engineering Support
DFM analysis, alloy selection guidance, design review, and prototype samples — before drawings are frozen and tooling is cut.
CNC & VMC Machining
Over 20 CNC turning centres and Vertical Machining Centres — including 4th-axis VMC for complex geometries.
Get Started
Sourcing Electric Mobility components?
Share your drawings — STEP, IGES, DXF, or PDF. We'll review manufacturability, confirm the right process and alloy, and respond with a technical and commercial assessment within 72 hours.