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The application of sand casting in new energy vehicle components

2024-07-04 11:15:05

The application of sand casting in new energy vehicle components

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Sand casting is a widely used method for manufacturing various components in new energy vehicles (NEVs). This traditional casting technique offers several advantages, making it suitable for the production of complex parts used in electric vehicles (EVs) and hybrid electric vehicles (HEVs). Here are some key applications and benefits of sand casting in NEV components:


  1. Motor Housings:

    • Sand casting is used to create intricate motor housings for electric motors. These housings must withstand high temperatures and provide precise dimensions to ensure efficient motor operation.

  2. Battery Housings and Trays:

    • NEVs require robust and lightweight battery housings and trays to protect battery packs. Sand casting allows for the creation of complex geometries that can integrate cooling channels and mounting features.

  3. Inverter and Converter Enclosures:

    • The power electronics in NEVs, such as inverters and converters, require enclosures that provide both thermal management and electromagnetic interference (EMI) shielding. Sand casting can produce these enclosures with integrated cooling fins and other design features.

  4. Structural Components:

    • Structural components like chassis parts, suspension arms, and subframes can be made using sand casting. This technique allows for the production of large, complex shapes with the required strength and durability.

  5. Gearbox Housings:

    • Gearbox housings in NEVs need to be strong and lightweight. Sand casting provides the flexibility to design housings with integrated features, reducing the need for additional machining.


  1. Design Flexibility:

    • Sand casting offers high design flexibility, enabling the production of complex shapes and geometries. This is particularly useful for NEV components that often require intricate designs for optimal performance.

  2. Cost-Effectiveness:

    • The initial tooling cost for sand casting is relatively low compared to other casting methods like die casting. This makes it an economical choice for producing small to medium-sized batches of NEV components.

  3. Material Variety:

    • Sand casting supports a wide range of materials, including aluminum, magnesium, and various alloys. These materials are commonly used in NEVs for their lightweight and high-strength properties.

  4. Rapid Prototyping:

    • Sand casting is suitable for rapid prototyping, allowing manufacturers to quickly produce and test new component designs. This accelerates the development cycle for NEVs.

  5. Scalability:

    • Sand casting processes can be easily scaled up for mass production, making it suitable for the growing demand in the NEV market.

  6. Complex Geometry:

    • The ability to cast complex geometries in a single process reduces the need for additional machining and assembly, leading to cost and time savings.


Despite its advantages, sand casting also presents some challenges:

  1. Surface Finish:

    • Sand cast components typically have a rougher surface finish compared to those produced by other methods like die casting. Additional finishing processes may be required.

  2. Dimensional Accuracy:

    • Maintaining tight tolerances can be challenging in sand casting. Post-casting machining is often necessary to achieve the desired precision.

  3. Porosity:

    • Sand cast components can exhibit porosity, which may affect their mechanical properties. Careful control of the casting process is needed to minimize this issue.

In conclusion, sand casting remains a valuable manufacturing technique for producing various components in new energy vehicles. Its flexibility, cost-effectiveness, and ability to handle complex designs make it well-suited for the evolving demands of the NEV industry.

Dongrun Casting have 20000 square meters facility houses and 200 production & test equipment, From quotation and tooling design to casting and finished machining, we  can work with you at every stage. We serves wide range of industries-from Fortune 500 corporations to small and midsize OEMs. Our products includes: Automotive&TruckingElectric Utility & Communications Metering SystemHydraulic IndustryMedical Devices LightingFuel and Gas PressureFurniture parts.

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