Bipolar plate 0.350 mm channel depth in 0.400 mm material.
micrometal is helping to promote the global agenda of sustainability, specifically concerning the electric vehicle industry. The precision metal parts manufacturer’s photo-chemical etching (PCE) processes, which include sheet PCE and reel-to-reel PCE, provide efficient and lightweight technologies for electric vehicles.
The main benefit of these types of processes is that they allow for the creation of precise and intricate designs while also reducing the potential risk of excess waste being produced. By utilising this PCE, the weight of components will be reduced, which means that electric vehicles will require less energy to operate as they are lighter. Consequently, this could lead to a reduction in carbon emissions being produced and the transportation sector becoming more environmentally friendly.
“In the context of EVs, PCE is particularly advantageous for the production of battery components such as current collectors and cooling plates. These components require high precision to ensure optimal performance and longevity,” said Jochen Kern, Head of Sales and Marketing at micrometal Group. “PCE allows for the creation of complex patterns and fine features that are essential for maximising the surface area and efficiency of current collectors. Compared to traditional manufacturing methods like stamping or laser cutting, PCE offers superior precision and uniformity, which are critical for maintaining the performance and reliability of EV batteries.”
Both heat exchangers and cooling systems can be produced using PCE processes, as it allows them to be both lightweight and efficient. Additional improvements to the thermal management of electric vehicles can also be achieved with PCE processes able to handle intricate and precise geometries which will ensure that batteries and electric components operate within safe temperature ranges.
“Another area where PCE drives innovation in EV technologies is in the fabrication of electrical connectors and busbars. These components require high conductivity and precise dimensions to ensure efficient power distribution within the vehicle,” continues Kern.
“PCE enables the production of connectors with complex shapes and fine details that are difficult to achieve with other manufacturing methods. This results in more reliable electrical connections, reduced energy losses, and improved overall efficiency of the EV's electrical system. The precision of PCE also allows for the integration of novel materials and designs that further enhance the performance of these components.”
Engineers can also utilise PCE to experiment with new designs and innovative ideas. This is because these processes unlock more complex geometries than previously available, allowing users to develop more compact and efficient components. In addition, PCE also allows for scalable and repeatable manufacturing which is ideal for mass production settings without risking quality assurance levels.
“PCE's environmentally friendly nature further aligns with the sustainability goals of the EV industry. The process uses often recyclable chemicals and generates less waste compared to traditional machining and manufacturing methods,” concludes Kern.
“This reduces the environmental impact of component production and supports the broader goal of creating a more sustainable manufacturing ecosystem. By combining precision, efficiency, and environmental benefits, PCE stands out as a superior manufacturing process that drives innovation and sustainability in the rapidly evolving field of EV technologies.”