Automotive Manufacturing: IATF 16949 & PPAP Discipline for Combustion and EV Programs
Bracketry, motor housings, cooling plates and busbars for vehicle and EV programs, produced under IATF 16949 with PPAP support, IMDS data and a control plan that travels with the part.
- IATF 16949
- PPAP level 1–5
- APQP & control plan
- IMDS submissions
- ISO 9001:2015 base
Program fit
Typical parts we manufacture for automotive programs
| Part type | Why we make it this way | Material families |
|---|---|---|
| Structural brackets and chassis fittings | 5-axis and 3-axis milling for high-strength lightweight shapes | 6061-T6, 7075-T6, high-strength steel |
| Motor and inverter housings | Precision milling on sealing faces with Cpk data on critical features | 6061-T6, A380 die cast (machined secondary) |
| Battery module structures and cooling plates | CNC milling, vacuum-brazed cooling plates and stamped manifold plates | 6061, 3003 aluminium, stamped steel |
| Busbars and high-current conductors | CNC machining and bending of copper and aluminium with controlled burr and plating | C110 copper, 6061, tin and silver plating |
| Connectors and charging hardware | High-volume precision turning and milling with contact plating | Brass, copper, stainless, engineering plastics |
| Plastic housings and insulators | Injection molding for production volumes, machined polymer for low volume | PA66, PBT, PPS, ABS |
| Aluminium extrusion frames and rails | Custom profile extrusion machined and finish-machined to length | 6061, 6063 |
Manufacturing route we recommend
- High-volume CNC machining for Tier-1 / Tier-2 production with a dedicated cell.
- CNC milling and turning for prototype and low-volume programs that still need production-grade documentation.
- Sheet metal fabrication for enclosures, brackets and stamped-and-formed components.
- Aluminum extrusion for frames, rails and thermal profiles.
- Injection molding for production-volume plastic housings, insulators and connectors.
- Inspection with PPAP including Cpk, MSA and capability data on critical characteristics.
Materials for automotive and EV programs
- 6061-T6 aluminium
- 7075-T6 aluminium
- 6063 aluminium extrusion
- C110 / C11000 copper
- H62 brass
- Cold-rolled steel
- Stainless 304 / 316
- PA66 (with and without glass fill)
- PBT, PPS, ABS
Material selection balances crashworthiness, thermal performance and cost. Reach out early so the material decision and the documentation plan are aligned.
EV-specific considerations
Busbars & conductors
- C110 copper machined to drawing with controlled burr
- Tin and silver plating options
- Insulation caps molded or assembled
- Hi-Pot testing on the busbar assembly
Battery modules & thermal
- Machined aluminium cold plates with vacuum brazing partners
- Stamped manifold covers in aluminium or steel
- Compression limiters and isolation hardware
- IMDS data and conflict mineral declarations
Recent project snapshot
EV fast-charge busbar assembly — copper plus insulator
A busbar assembly for a DC fast-charging station combined machined C110 copper conductors with a powder-coated aluminium bracket. Production moved through a dedicated cell after PPAP level 3 was approved, with Cpk data on the critical mating dimensions and IMDS entries filed for the materials.
- Process
- CNC turning and milling, powder coat, sub-assembly
- Tolerance
- ±0.05 mm on critical mating geometry
- Documentation
- PPAP level 3, IMDS, control plan, C of C
- Outcome
- 20 000 assemblies per year released on a six-week rolling schedule
Frequently asked questions
Are you certified to IATF 16949?
Yes. We confirm the current registration number, scope and expiry during quotation so nothing is assumed about the certificate status.
What PPAP levels can you support?
Levels 1 through 5, including dimensional results, material certificates, capability studies and control plan references as required by your purchasing team.
Do you file IMDS entries?
Yes. We submit IMDS data on request for OEM and Tier-1 programs and include the relevant material and substance declarations in the PPAP package.
What is your typical high-volume lead time?
For a new high-volume program, allow 8 to 12 weeks from PPAP approval to first serial delivery, including fixture build and production validation. Repeat orders run on the agreed Kanban or call-off schedule.
Can you handle small EV programs?
Yes. Prototype cells and low-volume runs share the same fixtures and quality plan as the eventual production cell, which removes the rework of a transfer.
Send the part number and the program requirements
Tell us the PPAP level, the documentation set and the forecast. We will confirm scope, lead time and the cell setup before quoting.