Die Cast EV Motor Controller Housings
IP67 is achieved by the assembly, not by the casting
Our EV motor controller housings are specified at IP67, and that rating is worth reading carefully. It describes the assembled unit: casting soundness, machined sealing faces, gasket compression and fastener spacing each contribute. A sound casting behind a poorly supported gasket land will still leak, and no amount of vacuum assistance will fix a flange that deflects between bolts. Agreeing which element each party owns during DFM prevents the disagreement that otherwise arrives at qualification.
Two drawing decisions carry most of the outcome: where the parting line and gate fall relative to the sealing face, and how much flatness is required across the gasket land. Flash at the parting line on a sealing face is entirely avoidable if the tooling is designed around it, but it is expensive to correct once the tool has been cut. Both are reviewed during our free DFM analysis before any tooling commitment.
Integrated cooling channels and structural rigidity
The housing is also a cooler and a structural member. Our motor controller housings are specified with integrated cooling channels and high structural rigidity, with CNC precision machining on the mating and mounting features. Cast-in channels avoid the contact resistance of a bolted-on cold plate, but they constrain the tooling: channel position has to be checked against ejector pins, insert pockets and the parting line before the tool design is frozen.
Rigidity is the other half of the requirement. A controller housing carries mounting loads and has to keep a sealed joint closed under vibration and thermal cycling, so section thickness and ribbing matter as much as the alloy. Where that geometry traps gas in the thicker sections, vacuum die casting is applied; our process chooses between conventional and vacuum routes during DFM rather than defaulting to either one.
Automotive documentation and verification
Automotive programmes are documented under IATF 16949 alongside ISO 9001, with RoHS and REACH compliance. Inspection reports and PPAP documents are available, and our QC laboratory provides CMM inspection, salt-spray testing and full batch reports with traceability by batch. If your qualification requires a leak test, state the method, the pressure and the acceptance criterion on the drawing so the inspection plan and the quotation both cover it from the start.
Send the STEP, IGES or DXF model with the sealing faces marked, the ingress rating required and the annual volume. DFM review is free with a reply within 24 hours, prototype samples in about 7 days and volume production in 30 to 45 days after approval, with EXW, FOB, CIF or DDP terms available to match your existing freight arrangements.
FAQ
Does the casting alone meet IP67?
No. IP67 describes the assembled unit. Casting soundness, machined sealing faces, gasket compression and fastener spacing all contribute, so we settle which element each party owns during DFM rather than at the qualification stage.
Can cooling channels be cast into the housing?
Yes, our motor controller housings are specified with integrated cooling channels. Channel position must be checked against ejector pins, insert pockets and the parting line during tooling design, so raise the layout at drawing stage rather than after machining.
Which documentation is available for automotive programmes?
IATF 16949 and ISO 9001, with RoHS and REACH compliance. Inspection reports and PPAP documents are available, together with CMM inspection data, salt-spray results and full batch reports traceable by batch.
How is sealing performance verified?
Tell us the test method, pressure and acceptance criterion and we build the matching inspection plan. Where a leak test is required, vacuum die casting is often the route we recommend for the gas-sensitive sections of the casting.
All figures above refer to standard product data sheets; final confirmation is subject to written quotation.