Custom CNC Machined EV PDU Housing

Electric Vehicle PDU Solutions
Custom High-Voltage Power Distribution Unit Solutions for EV Systems

Product Overview

Our Electric Vehicle PDU Solutions are designed for high-voltage power distribution systems in new energy vehicles, providing a comprehensive approach from structural design to key component integration. These solutions enable safe and efficient distribution of high-voltage power from the battery system to major subsystems, including the drive system, onboard charger (OBC), DC/DC converter, HVAC, and other auxiliary units.

Beyond supplying individual components, we offer integrated PDU development support. In addition to precision-engineered housings, we collaborate with customers on structural design and system integration, helping achieve higher levels of safety, system efficiency, and overall reliability within complex vehicle architectures.

Custom PDU Solutions for Vehicle-Level Integration

We provide flexible, project-based PDU development services tailored to different vehicle platforms and application scenarios. Our solutions go beyond enclosure design, taking into account internal electrical layout, interface compatibility, and system-level integration requirements.

During development, we support coordinated optimization of key design elements, including:

• High-voltage connector layout and interface design
• Busbar routing and structural integration
• Electrical clearance and insulation design
• Mounting configuration and vehicle packaging compatibility
• Sealing structure and environmental protection strategy

By aligning structural and functional design, we ensure reliable performance of the PDU within the overall vehicle system.

Core Housing & Manufacturing Capabilities

As a fundamental part of our PDU solutions, we bring extensive experience in enclosure design and manufacturing. Our housings are produced using aluminum die casting combined with precision CNC machining, with structural optimization supported by simulation to balance lightweight design and mechanical strength.

Critical sealing interfaces are machined to high precision to ensure flatness and dimensional consistency. Depending on project requirements, enclosures can be designed to meet various ingress protection levels (such as IP67 or IP6K9K).

The metal housing structure also contributes to electromagnetic shielding performance, helping reduce potential EMI interference in high-voltage environments. Through controlled manufacturing processes, we minimize risks such as porosity and deformation, ensuring consistent quality and long-term reliability.

Custom Development Inputs

To ensure efficient development of PDU solutions, customers are typically required to provide the following key information at the initial stage:

Ⅰ. High-voltage connector type and interface requirements

Ⅱ. Low-voltage control interface and pin definition

Ⅲ. Overall dimensions and packaging constraints

Ⅳ. Mounting method and interface requirements

Ⅴ. High Voltage Interlock (HVIL) requirements

Ⅵ. Labeling and identification specifications (warnings, barcodes, logos)

Ⅶ. Technical requirements (materials, protection level, surface treatment, etc.)

Ⅷ. Testing and validation requirements (leak testing, vibration, thermal conditions, etc.)

These inputs directly impact structural design, functional integration, and overall system performance.

Applications

• Passenger Electric Vehicles (EVs)
• Electric Buses and Commercial Vehicles
• Energy Storage Systems (ESS)
• High-Voltage Power Distribution Systems

Why Choose Us

We specialize in custom development of structural components and PDU solutions for new energy vehicles, offering integrated engineering capabilities from design through production. With a solid understanding of OEM development processes, we collaborate efficiently with vehicle manufacturers and system integrators to accelerate project timelines and improve development efficiency.

On the manufacturing side, we provide stable and scalable production capabilities, supporting the full product lifecycle from prototyping to mass production, including:

• PDU housing design and structural optimization
• Integrated die casting and CNC machining
• Rapid prototyping and iterative development support
• Support for project-specific testing and validation

Have a project in mind?
Contact us today to explore a tailored PDU solution for your EV application. Our engineering team is ready to support you from concept to mass production.