MetalCore delivers automotive-grade manufacturing for EV components, from lightweight structural parts to high-voltage thermal management systems. Built for performance, safety, and scale.
We engineer and produce mission-critical EV components using advanced alloys, polymers, and composites, meeting strict automotive safety and durability standards.
Lightweight, impact-resistant housings with integrated cooling channels and crash management structures. Optimized for energy density and thermal runaway protection.
High-precision stator cores, rotor shafts, and end bells manufactured with tight tolerances for minimal vibration and maximum efficiency.
Custom liquid cooling plates, heat exchangers, and micro-channel pumps designed for battery, motor, and power electronics cooling.
High-voltage busbars, DC-DC converter housings, and contact assemblies built for 800V architectures with full traceability.
From concept validation to full-scale production, our EV manufacturing division combines advanced machining, clean-room assembly, and rigorous validation testing.
Expertise in high-strength aluminum, magnesium, advanced steels, and engineering thermoplastics optimized for weight reduction and durability.
Design-for-manufacturability reviews, topology optimization, and simulation-driven engineering to reduce cost while maintaining performance.
In-house CMM, dimensional metrology, pressure testing, thermal cycling, and vibration analysis per OEM and SAE standards.
Automated lines, lean manufacturing cells, and just-in-time logistics supporting prototype, pilot, and high-volume production runs.
Full material pedigree, serialization, digital thread tracking, and comprehensive PPAP documentation for every production lot.
Zero-waste machining programs, closed-loop coolant systems, and carbon-neutral facility operations aligned with EV sustainability goals.
Our EV manufacturing processes are engineered to meet the most demanding automotive tolerances and material requirements.
| Parameter | Specification | Standard/Method |
|---|---|---|
| CNC Machining Tolerance | ±0.005 mm (±0.0002 in) | ISO 2768-mK / ASME Y14.5 |
| Surface Finish | Ra 0.4 - 3.2 μm | ISO 4287 |
| Material Capabilities | Al 5xxx/6xxx/7xxx, Mg AZ91D, Cu C11000, SS 304/316, PEEK, PPS | AMS / ASTM / ISO |
| Die Casting | Low-pressure, high-pressure, vacuum-assisted up to 800 tons | ISO 11963 |
| Welding & Joining | Laser, MIG, FSW, ultrasonic, adhesive bonding | SAE J2315 / AWS D17.1 |
| Thermal Testing | -40°C to +125°C cycling, steady-state & transient analysis | SAE J2523 / OEM Specific |
| Pressure Testing | Up to 1.5x operating pressure, helium leak detection | ISO 10349 / OEM |
Submit your project requirements for a detailed engineering review, material recommendation, and production timeline within 48 hours.