Case Study

800V 商用车 Busbar 端子嵌件成型

We engineered a heavy-duty insert molding process for 800V commercial EVs. Our structural design guarantees extreme thermal and mechanical resilience.

Industry: Leading Heavy-Duty Commercial EV Manufacturer - Tier 1
Material: High-Purity C11000 Copper & PA6 GF30
Volume: 250,000+ units/year
Lead Time: 8 weeks from DFM to SOP

Overcoming CTE Mismatch: Engineering 800V Busbar Terminals for Commercial EVs

We engineered a heavy-duty insert molding process for 800V commercial EVs. Our structural design guarantees extreme thermal and mechanical resilience.

Outcome Metrics

Operating Voltage: 800V+ HV Architecture
Insulating Matrix: PA6 / PA66 GF30
Conductor Insert: High-Purity C11000 Copper
Surface Plating: Matte Tin (Anti-whisker)
Validation: X-Ray void inspection & thermal shock
0% fracture rate on assembly line

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