Accelerating EV Production with Custom Manufacturing
Accelerate Electric Vehicle Innovation with Precision Component Prototyping and Scalable On-Demand Manufacturing
Services specifically tailored to the unique demands of
Electric Vehicles production
Multi-Cavity Variance Minimization
Real-time cavity pressure monitoring and digital mold flow validation ensure dimensional uniformity across cavities, reducing statistical deviation in critical EV geometries.
Material System Compatibility
Corrosion-resistant alloys and compatible surface treatments ensure structural and electrical performance in high-voltage, mixed-metal, and moisture-exposed EV assemblies.
Thermal Warpage Control
Thermal simulation and optimized cooling strategies reduce warpage in large EV castings, ensuring flatness and sealing integrity without post-processing.
Our Clients
End-to-End Supply Chain Management
Simplify your supply chain with Frigate’s comprehensive management solutions. We leverage our global network of partners to source materials at competitive rates, manage inventory levels to avoid stockouts or overstocking, and oversee production to ensure on-time delivery. This allows you to focus on core competencies like design and engineering, while we handle the complexities of the supply chain.
Reducing Porosity in High-Pressure Cast EV Housings
Porosity in structural castings can compromise pressure resistance, often requiring leakage rates <10⁻⁴ mbar∙L/s in battery enclosures and inverter housings.
Controlled cavity vacuum levels under 50 mbar reduce gas entrapment, particularly in flow-restricted zones of box-shaped enclosures.
Gate velocity control within this range ensures proper mold filling without turbulence, a primary cause of gas entrapment and shrink voids.
Advanced CT scanning with 10–25 μm resolution is used to inspect critical sealing regions and validate internal integrity before assembly.
Controlling Flatness in Large-Scale Castings
Battery trays and drivetrain covers require flatness <0.1 mm over lengths exceeding 600 mm, which is difficult due to solidification shrinkage.
Precision thermal control across die faces maintains solidification symmetry, minimizing warping in wide or asymmetrical geometries.
Simulation platforms (e.g., MAGMASOFT or ProCAST) model temperature gradients and predict deformation zones to adjust tooling and cooling strategies pre-production.
Dies reinforced with steel cores and minimal deflection under injection pressures >1000 bar maintain consistent cavity form and flatness.
Achieving EMC Conformance in Conductive Enclosures
Power electronics housings must meet CISPR 25 and ISO 11452 standards, often requiring shielding effectiveness >60 dB in the 1–1000 MHz range.
Alloys such as AZ91D provide structural performance and electromagnetic shielding, reducing radiated emissions without additional coatings.
Integrated casting features for electrical continuity keep contact resistance low, ensuring robust grounding for PCB and chassis connections.
Electroless nickel or zinc plating enhances contact reliability at mating surfaces and improves RF shielding around sensitive electronics modules.
Our Electric Vehicles Products
100,000+
Parts Manufactured
250+
Frigaters
2000+
Machines
450+
Materials
25+
Manufacturing Process
Industries We Also Serve
Having Doubts? Our FAQ
Check all our Frequently Asked Question
Frigate uses die casting techniques that control surface roughness to Ra < 1.6 μm. This ensures tight interface between the cast housing and power modules. Flatness is controlled within 0.1 mm to reduce thermal resistance between components and heatsinks.
Yes. Frigate can cast components using alloys compatible with overmolding or insert molding. For example, busbars made of copper or brass are cast into aluminum housings. Interface bonding is enhanced using interlocking geometries and thermal preheating of inserts.
Frigate selects high-thermal-cycle-resistant alloys like A360 and uses directional solidification to reduce hot spots. Castings are validated with thermal shock tests from -40°C to 125°C, ensuring long life under real field conditions.
Frigate uses mold filling simulations to manage metal flow and solidification timing. Wall thicknesses as low as 1.5 mm are supported. Die temperatures are balanced within ±10°C to reduce cooling stress and ensure final parts are tolerable.
Frigate integrates grounding features directly into the casting with designated current paths. Resistance across grounding points is tested to remain under 10 mΩ. For enhanced performance, selective plating and post-cast machining ensure clean metal-to-metal contact.
What Our Customers Say about Frigate
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LOCATIONS
Global Sales Office
818, Preakness lane, Coppell, Texas, USA – 75019
Registered Office
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
