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CNC Machined Aluminum 6061 EV Motor Housing for Electric Vehicles
Product Overview
EV motor housings represent one of the most demanding aluminum components we machine. While appearing deceptively simple externally, these housings require exceptional precision in critical areas including stator bore roundness, mounting face flatness, and leak-tight coolant passages. We machine these housings from Al 6061-T6 billet rather than castings to ensure zero porosity, consistent mechanical properties, and superior tolerance control.
Key Features
Stator Bore Precision: Roundness within 0.02mm, cylindricity within 0.03mm, surface finish Ra 1.6 - critical for maintaining proper air gap between stator and rotor
Mounting Face Flatness: 0.01mm flatness on transmission mounting face with perpendicularity to stator bore within 0.02mm
Coolant Passage Integrity: Internal passages machined by CNC drilling/milling, leak tested at 2 bar (30 PSI) for 10 minutes with zero leaks accepted
Threaded Hole Pattern: M5 or M6 bolt circles (36-48 holes) with position accuracy ±0.05mm relative to stator bore centerline
IATF 16949 Process Control: Full PPAP capability with process FMEA, control plans, SPC on critical dimensions, and MSA on measurement equipment
Technical Specifications
Specification
Details
Product Name
CNC Machined Aluminum 6061 EV Motor Housing
Material Options
Al 6061-T6 (standard), Al 6061-T651 (stress relieved), Al 7075-T6 (high performance)
Anodized Type II (black), Hard anodize Type III (coolant passages), Powder coat
Certifications
ISO 9001:2015, IATF 16949, RoHS, CE, REACH
Lead Time - Prototype
7-10 days
Lead Time - Production
15-25 days
MOQ
1 piece (prototype), 100+ (production)
Origin
Dongguan, China
Applications
EV Traction Motors: Main drive motor housings for BEV and PHEV applications
E-Axle Integrated Motors: Motor housings integrated with single-speed reduction gearbox
EV Auxiliary Motors: HVAC compressor, power steering, and brake booster motor housings
Electric Motorcycle/Scooter: Hub motor and mid-drive motor housings
Industrial Electric Motors: High-efficiency IE4/IE5 motor housings and servo motor housings
E-Bike/E-Scooter: Mid-drive and rear hub motor housings
Why Choose Our Manufacturing
EV Motor Housing Expertise: Extensive experience machining housings from 80mm to 300mm diameters
Billet Machining: Zero porosity risk with consistent material properties from certified Al 6061-T6 bar stock
Comprehensive Leak Testing: Every housing pressure tested with 2 bar air pressure and 10-minute minimum hold
Advanced Machining Capabilities: 4-axis and 5-axis CNC centers for maximum accuracy and minimum setups
Automotive Compliance: IATF 16949 certification with PPAP Level 1-3 capability
Thermal Management Expertise: Optimized coolant passage design review during DFM process
Manufacturing Process
DFM Review: Comprehensive design analysis including tolerance assessment, wall thickness evaluation, and coolant passage design review
Material Procurement: Certified Al 6061-T6 extruded or forged billet with material certificates
CNC Machining: 4-axis roughing, single-setup boring, face milling, drilling/tapping, and coolant passage milling
Coolant Passage Sealing: Threaded plugs, press-fit caps, or welded closures with integrity verification
Surface Treatment: Anodizing, hard anodizing, or powder coating applications
Inspection & Testing: CMM full layout, leak testing, surface finish verification, and PPAP documentation
Frequently Asked Questions
Why machine from billet instead of die casting?
Consistency. Die-cast housings can have porosity in coolant passage walls, which causes leaks. The material properties of cast aluminum are less predictable than wrought (6061-T6). Billet machining eliminates porosity risk and provides tighter tolerance capability.
Can you hold 0.02mm roundness on a 250mm stator bore?
Yes, in a single setup. We bore the stator bore after roughing external features using a single-point boring bar on a CNC machining center. The key is proper fixturing that supports the part without distortion and finishing with light DOC to minimize cutting forces.
What coolant passage designs can you machine?
Cross-drilled passages (simplest, most reliable), milled spiral channels (better heat transfer), or combinations. We recommend cross-drilled for most applications as they're easier to seal, inspect, and provide adequate thermal performance for most EV motor duty cycles.
Do you do the complete sub-assembly?
We machine the housing body, install and seal coolant passage plugs, and leak test. Stator installation, rotor bearing pressing, and end bell assembly are typically done at the motor manufacturer. Partial sub-assembly available on request.
What's the lead time for first article?
7-10 days for a billet-machined prototype housing. PPAP documentation adds 5-7 days. Production tooling requires 10-15 days. Ongoing production after first article approval is 15-25 days per batch.
Can you machine the matching gearbox housing too?
Yes. Many EV e-axle designs integrate motor and gearbox in common housing or have direct bolt-on configurations. We can machine both and ensure mating surfaces match perfectly using same fixture reference and inspection datum.
