Case Study: EV Charger

Case Study: EV Charger – CNC Machining vs Vacuum Casting

Client: EV Charger Manufacturer
Industry: Electric Vehicles
Product: EV Charger Enclosure
Objective: Validate enclosure design before tooling.

Challenge:

The client needed to validate both mechanical fit and aesthetic design quickly before tooling to ensure functional performance and visual appeal.

Solution:

CNC Machining:

• Precision: ±0.05 mm, used for mechanical fit and stress testing.

• Durability: High-strength parts for functional testing.

Vacuum Casting:

• Fast Turnaround: Produced in days for early design validation.

• Aesthetic Finish: PU resin parts mimicking final product's appearance.

Outcome:

• Speed: Both methods validated the structure and appearance in under 2 weeks.

• Cost-Effective: Efficient use of both methods saved time and money.

• Design Freeze: Quick validation allowed the team to confidently move forward with tooling.

Conclusion:

Using CNC machining for functional testing and vacuum casting for aesthetic validation helped the client rapidly validate design features and move towards production, reducing both time and risk.