Aluminum Automotive Components to Drawing

We machine aluminum automotive components to drawing: EV housings, ADAS brackets, cooling plates and heat sinks in 6061, 6082, 7075 and cast blanks.

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Introduction

Aluminum automotive components machined to drawing

Aluminum is the default material for EV, ADAS, electronics and thermal parts: it is light, it carries heat away from power devices and batteries, and it machines cleanly into flat sealing and mounting faces. We machine these parts to drawing, from engineering samples and pilot batches to low-volume and repeat production. Other metals and engineering plastics are listed under all machining materials.

  • Lot traceability from bar, plate or casting
  • CMM inspection of critical dimensions
  • FAI and inspection reports on request
  • Material certificates (MTRs) on request
Advantages

Machining considerations for aluminum parts

  • Thin-wall distortion

    Thin walls move as material is removed; roughing, stress relief and finishing are planned at the DFM review.

  • Stress-relieved plate

    T651 plate is stretched after heat treatment, so it stays flatter during machining than plain T6 plate.

  • Burr control

    Cross holes, ports and coolant passages are deburred and checked so no chips stay in fluid channels.

  • Galvanic corrosion

    Steel fasteners and inserts in aluminum need a coating or isolation, specified on the drawing.

Grades

Aluminum grades we machine for automotive parts

  • Aluminum 6061-T6

    EV and electronics housings, ADAS brackets, cold plates, heat sinks; good strength, conductivity and anodizing response, the general choice for housings.

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  • Aluminum 6082-T6

    Structural brackets, battery frame parts and mounting components. Higher strength than 6061 in extrusions and plate, good weldability.

    Al6082 vs Al7075
  • Aluminum 7075-T6 / T651

    High-load brackets and mounting components. Highest strength of the three, lower weldability, needs protection against corrosion.

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  • Cast blanks A380 / A356

    Motor and gearbox housings, valve bodies, cylinder heads in A380, ADC12 or A356-T6; we machine cast blanks to drawing; we do not cast aluminum.

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  • Aluminum 6061-T6
  • Aluminum 6082-T6
  • Aluminum 7075-T6 / T651
  • Cast blanks A380 / A356
Surface Finishes

Surface finishes for aluminum parts

Applications

Aluminum automotive components by application

  • EV and thermal

    Motor housings, inverter housings, battery enclosures, battery cooling plates, liquid cold plates and machined aluminum heat sinks.

  • ADAS and electronics

    ADAS sensor housings, camera mounts, ECU and BMS housings, machined to the customer's drawing.

  • Powertrain and transmission

    Cylinder heads, valve bodies and gearbox housings, machined from cast blanks to the customer's drawing.

  • Chassis

    Aluminum control arms and precision brackets. Each part is machined to the customer's drawing; we do not design the part or validate its function in the vehicle.

FAQs

Aluminum automotive components FAQ

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What car parts are made of aluminum?
Motor and inverter housings, battery enclosures, cooling plates, heat sinks, sensor housings, cylinder heads, transmission cases and suspension arms are common aluminum automotive components.
Is aluminum good for car parts?
Yes for weight-sensitive and heat-dissipating parts. Steel remains the better choice where very high strength or wear resistance is needed at low cost.
6061 or 7075 for an automotive bracket?
6061 is easier to weld and anodize; 7075 is stronger but less weldable. We recommend a grade after reviewing the loads and the joining method.
Do you machine die-cast aluminum parts?
Yes, we machine cast housings in A380 or ADC12 to drawing. On cast blanks, machined sealing faces can open porosity; impregnation or a leak test is agreed when the drawing requires it.
Which finishes do you offer on aluminum?
Hard anodizing, black anodizing and electroless nickel; other finishes when the drawing specifies them. Anodizing grows partly outward, so state on the drawing whether critical bores and threads are dimensioned before or after finishing.