{"id":35012,"date":"2025-12-17T11:10:43","date_gmt":"2025-12-17T03:10:43","guid":{"rendered":"https:\/\/firstmold.com\/?p=35012"},"modified":"2026-03-24T16:44:48","modified_gmt":"2026-03-24T08:44:48","slug":"ice-and-ev-parts-manufacturing-using-injection-molding","status":"publish","type":"post","link":"https:\/\/firstmold.com\/pl\/insights\/ice-and-ev-parts-manufacturing-using-injection-molding\/","title":{"rendered":"R\u00f3\u017cnica mi\u0119dzy produkcj\u0105 cz\u0119\u015bci do pojazd\u00f3w spalinowych a elektrycznych przy u\u017cyciu formowania wtryskowego"},"content":{"rendered":"\n

Since the manufacture of what is considered the first gasoline-powered car in 1885 by Karl Benz, the automobile industry has gone through waves of evolution [1]<\/a><\/sup>. The next phase in that evolution is new energy vehicles (NEVs). These are cars that rely on alternative power sources like electricity and hydrogen, instead of gasoline or diesel.<\/p>\n\n\n\n

Of all the different NEVs, battery electric vehicles, which run entirely on electricity stored in large battery packs, are favored because of easy access to electricity. This has led to demand for innovations in EV parts manufacturing. Many countries and regions around the world, including the UK, Canada, and Denmark, are set to stop the sale of diesel-powered vehicles (also called internal combustion engines or ICEs) between 2025 and 2040 [2]<\/a><\/sup>.<\/p>\n\n\n\n

China and some states in the United States have also set the target of banning the sale of new light and medium diesel and petrol vehicles by 2035. The shift in focus to manufacturing EV parts has necessitated a change in how manufacturers approach mold making<\/strong><\/a> and injection molding<\/strong><\/a>.<\/p>\n\n\n\n

\"EV<\/figure>\n\n\n\n

How EV Parts Manufacturing Differs from Traditional Vehicles<\/h2>\n\n\n\n

New energy vehicles usually have fewer moving parts compared to traditional vehicles. Also, the plastic parts used in NEVs usually have higher precision and performance requirements. Plastics with a high strength-to-weight ratio are favored to keep the weight of EVs low and improve battery efficiency.<\/p>\n\n\n\n

To achieve this, a wider range of plastics, including composites, engineering plastics, and post-consumer recycled resins (PCR), is often introduced. The projected compound annual growth rate of the PCR automotive market from 2025 to 2030 is 11.1% [3]<\/a><\/sup>. PCR is a cost-effective alternative to virgin plastic, which may account for its growing popularity.<\/p>\n\n\n\n

Vital parameters, including flow speed, temperature, and pressure, must be optimized during post-consumer recycled resins’ injection molding to create EV parts. The mold may be modified with specialized equipment, like degassing systems and filters, to manage contaminants and eliminate volatile compounds. Alternatively, low-pressure molding systems may be used to maintain the integrity of the PCR.<\/p>\n\n\n\n

Manufacturing EV parts with PCR consumes up to 80% less energy and emits fewer greenhouse gases compared to virgin plastics. Since the use of PCR aligns with the bigger picture of lowering carbon footprint and environmental sustainability, automakers who want to boost their environmental-friendly ratings will likely favor parts made with this material.<\/p>\n\n\n\n

Therefore, it is important to work with a mold maker that understands the peculiarities of manufacturing EV parts using PCR to create modified molds that will effectively handle this material. Below are other key differences that make the process of injection molding EV parts different from traditional vehicles.<\/p>\n\n\n\n

Design Complexity due to Parts Integration<\/h3>\n\n\n\n

Arguably, the major difference between NEVs and traditional vehicles is how power is generated and transmitted to the wheels. The table below shows how injection molding differs in making key components of ICEs and EVs.<\/p>\n\n\n\n

Parts<\/th>Traditional Vehicles<\/th>Electric Vehicles (EVs)<\/th><\/tr>
Main power source<\/td>Engine<\/strong>: contains pistons, valves, crankshaft, spark plugs, and timing belts that generate and transmit energy. This requires the creation of several small molds to make the different components<\/td>Battery pack:<\/strong> stores energy. This stored energy powers electric motors that drive the vehicle. EV battery casings are often made using a multi-cavity mold to lower per-unit cost and maximize production time<\/td><\/tr>
Cooling system<\/td>Uses radiator, water pump, and thermostat for cooling. Just like the engine, the cooling system involves several small parts, and some of them are made using injection molding and assembled<\/td>Use fans to circulate ambient air, electric water pumps that circulate coolant, or both. The grilles, which are designed to help with air circulation, are often made using multi-component injection molding<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

EV battery casings, for example, are usually made with advanced composites with a focus on a high strength-to-weight ratio to provide structural support, assist with thermal management, and fire safety. EV battery casings usually have a complex design, which must be met without affecting their function. This and several other parts require intricate mold designs with complex sliders, cooling channels, and, in some cases, multi-shot molding capabilities.<\/p>\n\n\n\n

Higher Emphasis on Precision and Tolerance<\/h3>\n\n\n\n

The core requirement during the production of traditional automobile parts is usually on appearance (achieving a glossy surface and smooth texture to touch) and weather resistance, while keeping the production cost low.<\/p>\n\n\n\n

On the other hand, the focus during the production of EV parts is more about achieving higher precision and tighter tolerance, especially for sensitive parts related to battery systems and electronic components. Molded EV parts must achieve a snug fit, since Noise, Vibration, and Harshness (NVH) problems are more noticeable in EVs compared to traditional vehicles [4]<\/a><\/sup>. Higher precision also ensures the reliability and safety of electronic components. While manufacturing EV parts, some of the design considerations for tight tolerance include:<\/p>\n\n\n\n