1. Body and Structural Parts (Lightweighting is Key)
This is the most widely used and traditional application of stamping technology. To achieve longer driving range, new energy vehicles have extremely high requirements for lightweighting their bodies, resulting in the extensive use of high-strength steel and aluminum alloys.
Body Panels:
Doors, hoods, and trunk lids: Exterior panels require smooth and aesthetically pleasing surfaces, while interior panels require complex structures to provide rigidity and mounting points.
Roof and side panels: Large panels require high rigidity and dimensional accuracy.
Fenders: Aluminum alloys are often used to reduce weight.
Body Structural Parts:
A/B/C pillars, sill rails, longitudinal beams, and cross beams: These form the vehicle's "skeleton," utilizing extensive hot stamping of ultra-high-strength steel to protect the passenger compartment in a collision while also achieving lightweighting.
Battery Pack Housing Structural Parts: The battery pack is the "chassis" of new energy vehicles. Its housing frame, cross and longitudinal beams, and other components also utilize extensive stamping, requiring high strength and rigidity to protect the battery cells within.
II. Battery System (Core of New Energy Vehicles)
The battery pack is a unique and high-value component of new energy vehicles, containing numerous precision stamped parts.
Battery Pack Housing:
Upper and lower housings: Typically stamped from aluminum alloy or high-strength steel, they require to be lightweight, strong, well-sealed, and able to withstand certain impacts and compression.
Internal Supports and End Plates: Used to secure the battery cell module and prevent it from shaking, they are typically stamped from steel sheet.
Cell Connection and Module Components:
Busbars: These are crucial precision stamped parts. They connect individual battery cells and conduct high currents. Typically stamped from copper or aluminum, they require extremely high precision and conductivity.
Module Side and End Plates: Components that form the battery module's frame structure.
Battery Explosion-Proof Valve: A precision stamped part that ruptures to release pressure when internal battery pressure exceeds the specified limit, ensuring safety.
3. Electric Drive System (the "heart" of new energy vehicles)
Many stamped parts are also found in the motor and electronic control systems.
Motor Housing: Protects the stator and rotor within the motor and is typically made of die-cast aluminum alloy or stamped and welded.
Motor Internal Laminations: The stator and rotor of the motor are made of a large number of laminated silicon steel sheets, which are manufactured through precision stamping. The quality of this stamping directly affects the efficiency and performance of the motor.
Inverter/Electronic Control Housing: Protects the delicate internal circuitry and requires excellent heat dissipation and electromagnetic shielding performance. It is often made of aluminum alloy stampings.
Heat Sink: The heat sink for the motor and electronic control consists of a large number of aluminum fins, which are often stamped.
4. Chassis and Suspension System
Subframe: The subframe of some models is made of stamped and welded steel sheets.
Control Arms and Links: Components of the suspension system, increasingly made of aluminum alloy forging or stamping and welding processes to achieve lightweighting.
Brake disc dust covers, fuel tanks (if any), etc.
V. Other Common Components
These components are found in both conventional and new energy vehicles.
Seat frames: Utilize a large number of high-strength steel tubes and steel plate stampings.
Air conditioning system components: Such as cooling fins and air ducts.
Various brackets and mounts: Found throughout the vehicle, they secure various devices, such as sensor brackets and wiring harness clips.
Stampings in new energy vehicles are evolving from traditional structural and functional components to a hybrid design combining "structural function + power electronics function + extreme lightweighting." High-precision, high-functionality stampings like busbars and motor laminations have a far higher technical threshold and value than traditional stampings. It can be said that the rise of new energy vehicles has not eliminated the stamping process; instead, it has driven its development towards greater precision, higher efficiency, and a wider range of material compatibility, making it one of the key technologies supporting new energy vehicle manufacturing.