Precision Manufacturing Capability: Achieving Critical 0.012mm Tolerances for Aluminum Housings

At EMP Tech, we specialize in high-precision aluminum components for EV, electronics, and automotive applications. Our advanced manufacturing processes consistently achieve tolerances as tight as ±0.012mm, ensuring optimal performance for mission-critical parts like motor controller housings and battery enclosures.

Tolerance Standards & Capabilities

• ISO 2768 Compliance:

• Linear dimensions (e.g., length, diameter): ±0.012mm under ISO 2768-m (medium grade) for sizes 30–120mm.

• Geometric tolerances (flatness, perpendicularity): 0.02mm at Grade K (high precision).

• Surface Finish:

• Ra 0.4–0.8µm via CNC finishing, eliminating porosity risks inherent in die casting.

• Industry Benchmark:

• Exceeds standard CNC tolerance (±0.025mm) and die casting (±0.1mm), ideal for sealing surfaces and thermal management components.

Technical Enablers for 0.012mm Precision

Factor	Implementation at EMP Tech
Equipment	5-axis CNC mills (±0.005mm repeatability) + robotic FSW systems for seam-free welding 1.
Material Science	6061/7075 alloys (yield strength: 200–500 MPa), optimized for minimal thermal deformation during machining.
Process Control	In-line CMM inspection + AI-driven thermal compensation to maintain ±0.012mm in mass production.
Post-Processing	Micro-milling & honing for critical features (e.g., sensor mounts, coolant channels) 14.

Certification & Quality Assurance

• ISO 9001/AS9100D: Full traceability from billet to final part.

• Metrology: 100% full-dimension inspection reports with GD&T compliance (e.g., true position ≤0.01mm).

• Defect Rate: <0.1% for porosity/cracks via proprietary FSW (Friction Stir Welding) technology.

Applications: Precision-Critical Components

• EV "3-Electric" Systems:

• Motor controller housings (flatness ≤0.015mm for IGBT module bonding).

• Charger enclosures (IP67 sealing with ±0.012mm dimensional stability).

• Electronics: Heat sink plates (Ra 0.4µm for optimal thermal contact).

• Automotive: Transmission valve bodies (bore concentricity ≤0.01mm).

Industry Trends & EMP Advantages

• Lightweighting: Achieves 1.5–3mm thin walls via hybrid casting + CNC, 20% lighter than pure-machined parts.

• Cost Efficiency: Combines die casting (high-volume rough shaping) + targeted CNC (±0.012mm critical zones), reducing cost by 30% vs. full CNC.

• Agility: 15-day rapid tooling revision for design iterations.

Why EMP Tech?

• Technology: Robotic FSW for hermetic sealing of high-voltage housings.

• Precision: 0.012mm tolerance certified for 95% of production batches.

• Scalability: Supports 10–100,000pcs/month with KPI-driven OTIF (On-Time-In-Full) delivery. Explore our capabilities:  www.empcasting.com.

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