We machine busbars, heat sinks, inverter housings and structural brackets from production-grade metal. One prototype or a 10,000-part run, inspected before it ships.
These are the failures we see most often on energy hardware programs.
Cross-section and surface condition drive resistance. If the machined edge is rough or the bend radius is wrong, current density concentrates and the part heats up in test. The fix is a machined profile held to a tight tolerance, not a cut-and-file job.
A base that is not flat leaves air gaps at the interface. Thermal resistance climbs, junction temperature rises, and the whole assembly needs a redesign. Flatness on the mounting face has to be controlled at the machine, not shimmed later.
Hole positions drift between the first article and the tenth. The welder forces the part, the coating cracks, and the line stops while someone reworks it. Positional tolerance on bolt holes is what keeps this from happening.
The first five parts look fine. Then the order grows and the process changes, so the parts no longer match the validated samples. Re-qualification eats weeks you had already committed to your customer.
Prototype and production on the same machines, so the part you qualify is the part you buy.
Copper and aluminium behave differently at the spindle. Copper grabs the tool and pushes heat into the workpiece, so we adjust feed, speed and coolant before the first cut instead of after. Aluminium 6061 and 6063 move fast, but thin walls deflect if the fixture is soft.
For busbars we hold the machined profile and the hole pattern in one setup where possible. That keeps the pitch between bolted connections consistent, which matters when the bar lands on a laminated stack or a welded frame.
A heat sink is a flatness problem before it is a fin problem. We face the base in a single pass and measure it, because a base that rocks by 0.02 mm is a base that will not transfer heat the way the simulation predicted. Fin thickness is set by the tool you can actually run, not by the drawing alone.
Enclosures and brackets usually start as a machined or cast blank and end up as a coated part. We keep the machining datum and the coating datum the same so the mounting features stay where the assembly expects them.
Use this to pick a process before you commit tooling money.
| Part type | Best first route | Why |
|---|---|---|
| Busbar, small batch | CNC milling | Profile and hole pattern in one setup. |
| Heat sink base | CNC milling | Flatness controlled at the face. |
| Housing, complex ribs | 5-axis machining | Fewer setups, tighter position. |
| Bracket, thin plate | Sheet metal | Faster and cheaper than milling. |
| Enclosure, higher volume | Die casting + CNC | Tooling pays back above a few thousand. |
| Seal, gasket, cover | Vacuum casting | Low tooling cost for the first build. |
Six routes, matched to the part and the volume.
Sixteen simultaneous 5-axis centers for housings, impellers and parts with angled features that would need three fixtures on a 3-axis mill.
Shafts, connectors, threaded inserts and turned bosses. Mill-turn centers keep a turned bore and a milled flat concentric in one cycle.
Machined prototypes from the production alloy so the first test is a real test, not a plastic stand-in that behaves differently.
Brackets, trays and covers. Laser cut, formed and finished, with hole patterns that match the machined parts they bolt to.
Aluminium housings and frames once volumes justify tooling. ADC12 and similar alloys, with machining and finishing after the cast.
Anodizing, plating, powder coating, bead blasting and laser marking. Conductive anodizing is available for parts that need a ground path.
Numbers from our own equipment list.
| Item | Specification | Note |
|---|---|---|
| Maximum part size | 4,000 mm | Longest travel on the large mill. |
| Large travel | 4,000 × 400 × 150 mm | Extrusions, rails, long busbars. |
| Medium travel | 750 × 1,150 × 550 mm | Most housings and plates. |
| Compact travel | 500 × 500 × 450 mm | Small brackets and connectors. |
| Tolerance | ±0.005 mm | On features that need it. |
| Fine finish | Ra 0.2–0.8 μm | Sealing faces and sliding fits. |
| Standard finish | Ra 1.6–3.2 μm | General machined surfaces. |
| Inspection | 100% before shipment | Reports on request. |
Six things that decide whether an energy prototype program stays on schedule.
Three wholly-owned plants and 150 technicians. The same team handles the prototype and the production run, so nothing is handed to a stranger at the volume step.
Tight fits are machined and measured, not assumed. When a feature cannot hold that number, we say so before the job starts.
Send a model and get a price plus a manufacturability note. Production can begin within 24 hours of approval.
Standard turnaround on machined parts. Historical late-delivery probability sits below 2%.
From a single prototype to a 10,000-part run, with no minimum order quantity.
Raw material check, in-process monitoring and final inspection. Reports are issued on request.
Busbars and module brackets where hole pitch and flatness decide whether the pack assembles without force.
Inverter and converter enclosures that must seal, ground and dissipate heat at the same time.
Cold plates and heat sink bases held flat at the mounting face so the interface does the work it was designed for.
Mounting rails and frame brackets machined to the same datum as the coated finish.
Yes, with light radial engagement and sharp tooling. Copper burrs form fast when the tool rubs, so we cut with a positive rake and control the heat instead of pushing the feed.
Edges that will be handled during assembly can be deburred or chamfered as part of the operation. Tell us where the contact surfaces are and we will keep them clean.
On a faced base we work to the flatness called out on your drawing, and we measure it before the part leaves the machine. If a base is thin relative to its size, clamping pressure alone can distort it during measurement.
When the base is too thin to hold the number without stress relief, we tell you before machining rather than after.
There is no minimum order quantity. One prototype and a 10,000-part run both go through the same process planning.
Small runs are machined from solid or plate. Larger runs may move to die casting or another route if that is cheaper for you, and we will say so in the quote.
Aluminium 6061, 6061-T6, 2024, 5052, 5083, 6063, 6082 and 7075, plus ADC12 for castings. Copper grades include C101, C103 and C110, with beryllium copper available.
Stainless 303, 304, 316 and 17-4PH cover most fastening and wet-environment parts. Titanium and Inconel are machined when the application needs them.
Uploads are secure and confidential. We can sign your NDA, or use our own non-disclosure agreement if you do not have one ready.
Files are kept inside the project team. If you need to limit who sees the model, tell us at the quote stage so we can set that up before any machining starts.
That is the point of running both on the same equipment. The prototype is machined from the production alloy on the machine that will eventually make the parts.
When the design freezes, the process plan carries over. You avoid the re-qualification step that happens when a prototype shop and a production shop are two different companies.
Conductive anodizing and selective masking keep contact areas live while the rest of the part is coated. Electroless nickel, silver and gold plating are also available.
Laser marking is limited to a minimum character height of 1.5 mm. Small serial numbers need to be sized accordingly.
Quotation and DFM analysis come back within 12 hours. Production can start within 24 hours of approval, and parts typically ship in 3–5 days.
If your model has a feature that cannot be machined as drawn, the DFM note will flag it before the schedule is set.
Upload a drawing or STEP file and we will return a price, a DFM note and a realistic lead time.
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
CNC Metals 13 grades
CNC Plastics 10 grades
Machines & processes 12 options
Surface & post-processing 10 options
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