BYD Custom Automotive Parts Aluminum Die Casting Manufacturer
Automotive OEMs like BYD require structural components that meet extreme performance, safety, and production scale standards. With precision aluminum die casting, we deliver lightweight, corrosion-resistant parts that support next-generation electric vehicle designs.
Our advanced casting systems and tight-tolerance post-machining allow for structural consistency and thermal performance critical in EV motor housing, inverter bases, and suspension brackets.
Structural Aluminum Casting for Lightweight Automotive Integration
Aluminum’s strength-to-weight ratio makes it indispensable for modern vehicle architecture. Components such as transmission housings, motor mounts, and control modules benefit from the high dimensional stability and thermal conductivity of die-cast aluminum alloys like A380 and A360.
Key casting specifications:
Minimum wall thickness: 2.0 mm
Tolerances: ±0.1 mm as-cast, ±0.02 mm post-machining
Tensile strength: up to 320 MPa (A360)
Thermal conductivity: 96–110 W/m·K
Porosity: <1% (X-ray verified)
Aluminum die casting is ideal for EV components that demand strength and conductivity.
Alloy Selection Based on Vehicle Function and Environment
Different sections of a vehicle require different performance metrics. A360’s thermal conductivity and corrosion resistance outperform traditional die-cast materials for thermal zones like inverters or battery enclosures. A356 is preferred for components requiring post-weld processes due to its improved elongation.
Alloy | Yield Strength | Conductivity | Use Case |
|---|---|---|---|
A380 | 170 MPa | 96 W/m·K | Control units, brackets |
A360 | 190 MPa | 110 W/m·K | Motor housings, inverter bases |
A356 | 160 MPa | 100 W/m·K | Welded structural frames |
AC4C | 210 MPa | 130 W/m·K | Battery tray, powertrain housing |
Explore more about our automotive aluminum alloys tailored to EV applications.
Post-Machining for Precision-Fit Assembly
In automotive applications, tight-fitting components ensure minimal vibration, improved NVH (noise-vibration-harshness) behavior, and optimal alignment. Using high-speed 5-axis CNC centers, we perform post-processing on critical surfaces and functional holes.
Common secondary operations:
Flatness milling: ≤0.05 mm
Threaded hole tapping: ISO metric and UNC
Pin bore reaming: ±0.01 mm
Coaxiality and perpendicularity inspection via CMM
See how our post-machining services support Tier 1 automotive assemblies.
Surface Treatments for Durability and Corrosion Resistance
Aluminum die castings in automotive environments are exposed to road salts, moisture, and temperature cycling. To protect them, we apply:
Powder coating: 1,000+ hour salt spray life (ASTM B117)
Anodizing: dielectric insulation and enhanced surface hardness
E-coating and chromate passivation for underbody assemblies
Each coating system is qualified through thermal shock, adhesion (ASTM D3359), and UV resistance testing.
High-Volume Production and APQP Quality Control
Supporting the automotive sector requires meeting strict quality systems such as IATF 16949 and the Advanced Product Quality Planning (APQP) framework. Our quality assurance includes:
Process FMEAs for all casting tools
First Article Inspections with ballooned drawings
PPAP documentation and full traceability
Inline X-ray and real-time SPC dashboards
Our mass production workflows enable monthly volumes exceeding 250,000 units, maintaining Cpk ≥ 1.67 on safety-critical features.
FAQs
What aluminum alloys are best suited for structural electric vehicle parts?
What surface treatments improve aluminum component durability in automotive environments?
How are dimensional tolerances maintained for large-volume automotive castings?
What certifications and documentation are required for automotive casting suppliers?
What secondary machining operations are critical for EV powertrain integration?
