As vehicles go electric, lightweighting is key to boosting range and cutting energy use. Studies show that every 10% weight cut improves EV range by 6–8%. Aluminum extrusions are widely used in battery trays, crash beams, frames, and motor housings due to their light weight, high strength, formability, and corrosion resistance. By 2028, aluminum content per car is expected to exceed 250 kg.
This trend raises new demands on extrusion equipment:
Higher tonnage and precision needed: Large-section, thin-wall, and complex-profile extrusions are becoming standard. Presses must deliver higher clamping force, smoother speeds, and tighter temperature control. Traditional small-to-medium presses fall short.
Stricter demands on productivity and stability: EV parts require fast, high-volume production with tight deadlines. Presses must run continuously and reliably, minimizing unplanned stops while ensuring consistent dimensions and surface finish.
To meet these challenges, press makers should upgrade in these areas:
Optimize frame rigidity: Use pre-stressed frame designs to boost fatigue strength and prevent deformation under high tonnage, improving profile accuracy.
Upgrade control systems: Apply servo electro-hydraulic hybrids for stepless speed control and closed-loop pressure regulation. This allows precise speed adjustments per stage, better suiting thin-wall and complex profiles.
Add full-line automation: Include dual pullers, online quenching, and automatic cooling beds to automate from billet heating to finished stretching, meeting automakers' high-volume, fast-turnaround needs.
These directions are now industry standards and key focus areas for press suppliers serving the EV supply chain. HENGDA Machinery continues to track lightweighting trends, evolving our products in high-tonnage, high-precision, and high-automation to offer more adaptable solutions for our customers.
