Custom Silicone Components and Plastic Housing Solutions for Automotive and Electric Vehicle Accessories
In the rapidly evolving automotive and electric vehicle (EV) sectors, customized silicone parts (such as seals, gaskets, O-rings, thermal pads, hoses, vibration dampers, and soft-touch grips) combined with precision plastic shells/housings (for chargers, battery enclosures, sensor covers, EVSE connectors, power distribution boxes, dashboard accessories, LED light housings, and antenna modules) are critical for performance, safety, reliability, and cost-efficiency. These solutions address unique demands like extreme temperature cycling (-60°C to +230°C+), IP67/IP68 waterproofing, vibration resistance, EMI shielding, flame retardancy (UL94 V-0/V-1), thermal management for batteries, chemical resistance to coolants/electrolytes, and long-term compression set performance under 20+ years of service life.
Advanced Silicone Parts Solutions (LSR & High-Performance Elastomers)
Liquid Silicone Rubber (LSR) injection molding is the gold standard for high-volume, high-precision automotive/EV parts. Unlike traditional compression molding or peroxide-cured silicone, LSR offers:
- Superior flow for thin-wall, complex geometries (wall thickness down to 0.5mm).
- Excellent tear strength, elongation (>300-800%), fatigue resistance, and ultra-low compression set (<10% after aging).
- Inherent resistance to UV, ozone, weathering, automotive fluids (oil, fuel, glycol), and dielectric strength for high-voltage isolation.
- Custom formulations: medical/food-grade, flame-retardant, thermally conductive (1-3 W/m·K for battery TIM pads), electrically conductive (nickel-graphite filled for EMI gaskets), fluorosilicone (FVMQ) for aggressive chemicals, and low-outgassing grades.
Key EV Applications:
- Battery pack module-to-module gaskets and enclosure seals (prevent thermal runaway by restricting oxygen/moisture ingress, achieving IP68 + thermal cycling 5000+ cycles).
- Thermal interface materials (gap fillers, soft pads) for cell-to-cooling plate heat transfer.
- High-voltage connector seals, busbar insulation, and potting compounds.
- Charger plug boots, O-rings for EVSE (UL 2202 compliant), and vibration-isolating mounts that reduce NVH.
Overmolding & 2K/Multi-Shot Integration: LSR is directly bonded to plastic substrates (PC, PC/ABS, PA66, PBT) or metal in one automated cycle. This creates permanent, leak-proof assemblies eliminating secondary gaskets, adhesives, or assembly labor—saving 30-50% on total cost while ensuring seal integrity under shock/vibration. Robotic insert placement + LSR injection delivers tolerances of ±0.05mm and billions of defect-free parts.
Precision Plastic Shell & Housing Solutions
High-volume injection molding (including gas-assisted, thin-wall, and insert molding) for rigid housings:
- Materials: Flame-retardant PC/ABS, PC, PA6/PA66 (GF15-45% for stiffness), PBT, PPS for high-temp battery boxes, UV-stabilized ASA for exteriors, conductive compounds for EMI, and recycled/bio-based options.
- Features: Snap-fits, living hinges, threaded inserts, textured surfaces (soft-touch, leather-grain), integrated clip features, vents with membranes, and hybrid overmolded LSR gaskets.
- EV-Specific: Charger station enclosures, portable charger housings, battery management system (BMS) covers, sensor radar housings (radar-transparent), and lightweight powertrain components that improve range by 2-5%.
Full Turnkey Customization Process
- Design & Engineering Support — DFMEA, FEA (thermal, vibration, sealing simulation), CAD (Catia/SolidWorks), material selection, and rapid prototyping (SLA/FDM tools + vacuum-cast LSR in 3-5 days; 3D-printed silicone in 24-48 hrs).
- Tooling — In-house P20/H13 steel molds (single/multi-cavity, hot runner, 2K rotary), aluminum for prototypes (500-5k shots).
- Production — From 100 pcs (bridge tooling) to 10M+ pcs/year on fully automated LSR presses (100-500 ton) and hybrid 2K machines. Cleanroom (Class 8) options available.
- Secondary Operations — Post-curing, plasma treatment for adhesion, laser marking/etching, pad printing, assembly, functional testing (leak, thermal shock, salt spray, EMC).
- Quality & Compliance — IATF 16949:2016, ISO 9001, PPAP, FAI, material certs (UL, RoHS, REACH, SVHC, FMVSS 302), 100% automated vision inspection, and traceability.
Competitive Advantages & Trends
- Cost & Speed: Tooling in 10-20 days; unit price competitive even at mid-volume (1k-50k pcs).
- Sustainability: Recycled PC/ABS, bio-based silicones, lightweight designs reducing EV battery weight.
- Future-Proof: Support for 800V+ architectures, autonomous vehicle sensors, and solid-state battery sealing.
Real-World Examples:
- Overmolded LSR gasket on PC/ABS EV charger housing → reduced assembly from 3 steps to 1, passed 10,000 mating cycles + IP68.
- Custom thermally conductive silicone pads for 2170/4680 cell modules → improved cooling efficiency by 15-25%.
- Flame-retardant silicone sponge enclosures for Level 2 chargers → UL 50E/UL 94 V-0 compliant, outdoor durability 15+ years.
This integrated silicone + plastic solution delivers lighter, safer, more reliable accessories that enhance EV range, reduce warranty claims, and accelerate time-to-market. Whether you're an OEM, Tier 1, or aftermarket supplier, we provide end-to-end support from concept to mass production. Contact us today for a free DFM review and quote!
