The processes and materials used in the manufacturing of sheet metal modification parts for new energy vehicles

• The processes and materials used in the manufacturing of sheet metal modification parts for new energy vehicles
  • What are automotive sheet metal parts ?
  • Different processing technologies for manufacturing sheet metal parts for new energy vehicles
  • Types of materials used in sheet metal parts for new energy vehicle modification
  • Factors affecting the manufacturing cost of automotive aftermarket sheet metal parts
  • How to estimate the manufacturing cost of automotive aftermarket sheet metal parts
  • Your trusted automotive body panel parts manufacturing and design company
  • Conclusion
  • FAQ

new energy vehicles typically requires the custom production of high-quality sheet metal parts using various processes and materials . These parts are key components of vehicle modification and repair. This complex process involves the precise shaping of parts to form various automotive components, including fenders and body panels. Materials typically range from high -strength and durable cold-rolled steel to rust-resistant and wear-resistant specialty alloys .

Generally, the thickness of automotive sheet metal parts is a crucial factor, determining the purpose of each part and ensuring compatibility with the original designs of different car manufacturers . Traditional and advanced metalworking techniques are key means of manufacturing these components . Sheet metal processing is one of the core processes in the automotive modification industry. This article will delve into the various processes and materials used in the manufacturing of sheet metal parts for modified new energy vehicles .

I will delve into the nuances of metalworking, from selecting premium sheet metal for car repair to the intricate processes of crafting durable and aesthetically pleasing aftermarket parts . Whether you are a professional in an auto repair shop or an amateur enthusiast interested in car modifications , this article will provide you with invaluable knowledge to enhance your craft.

What are automotive sheet metal parts ?

Automotive sheet metal parts refer to cold-rolled flat steel used in the manufacture of automotive components. Precision sheet metal processing technology can produce durable original metal parts for vehicle body repair and modification , including parts requiring modification and rust prevention repair such as front lips, fenders, and side panels .

Customized automotive sheet metal parts are a crucial business for auto repair and modification shops . They need to provide replacement parts and custom sheet metal parts for customers modifying new energy vehicles , based on market demand, for comprehensive vehicle modification, repair , and maintenance. Therefore, choosing high-quality sheet metal processing techniques ensures the lifespan and compatibility of the required automotive parts. Automotive sheet metal parts are made using advanced processes and manufacturing technologies , which are essential for maintaining the structural integrity of the vehicle, while also contributing to a vehicle modification that is both aesthetically pleasing and functional .

Different processing technologies for manufacturing sheet metal parts for new energy vehicles

Understanding the diversity of metalworking technologies is crucial, especially in sectors like the new energy vehicle industry. These methods enable the manufacture of a wide range of critical components, from vehicle bodies to complex structural parts. Each technology offers unique advantages and applications, making them indispensable tools for manufacturing modified sheet metal parts or replacing panels. Below, we will delve into the various methods for manufacturing sheet metal components for new energy vehicles .

Stamping	This process involves stamping flat metal sheets, typically in gauges 20 or 22, into the desired shape. It is a key process in manufacturing the large panels that make up the car body. The stamping process enables high-volume production, ensuring the efficient manufacture of the necessary aftermarket parts.
Hydraulic forming	Hydroforming uses high-pressure fluid to shape metal within a mold. It is advantageous for manufacturing complex shapes for automotive parts, providing high precision while maintaining metal integrity. This method is particularly well-suited for parts requiring 22-gauge sheet metal, thereby enhancing service levels in the automotive aftermarket industry.
Laser cutting	Laser cutting uses a high-powered laser to cut precise shapes into metal, making it ideal for complex designs or automotive parts requiring accurate dimensions. Its high precision makes it suitable for automotive aftermarket sheet metal parts and replacement panels.
Welding	Welding is the process of joining metal parts together using heat. It is a fundamental technique in assembling automotive body structural components, ensuring the durability and safety of vehicles. Welding services are essential for the automotive industry in both manufacturing aftermarket parts and repairing existing components.
Deep stretching	Deep drawing dies stretch metal into deep, irregular shapes. This method is used to manufacture components such as fuel tanks or certain body panels, typically using 20 and 22 gauge sheet metal. It allows for the production of complex parts without sacrificing the metal’s strength.
Bending	Bending processes can create V-shapes, U-shapes, and channel shapes on metal sheets. This technology is crucial for forming automotive frames or structural components, as it allows for flexible use of cold-rolled flat steel.
Punching	Punching is the process of creating holes or cuts in metal using a punch press. It’s a crucial process for parts requiring ventilation or mounting points and is widely used in the automotive aftermarket . Punching ensures precise holes are formed in both original metal sheets and replacement panels.

Each technology plays a vital role in metalworking, especially in the automotive aftermarket industry. They enable the precise and efficient manufacture of all components, from car bodies to various precision automotive parts. The efficient use of appropriate tools and methods allows for high-quality sheet metal processing, meeting the design and safety standards of modern new energy vehicles.

Types of materials used in sheet metal parts for new energy vehicle modification

Understanding the various materials available is crucial for achieving optimal results in any custom automotive sheet metal parts project, especially in the automotive aftermarket service industry. Each material possesses unique properties, from durability to corrosion resistance, impacting everything from safety components to fuel efficiency. Selecting the right materials and specifications is essential for metalworking services, panel fabrication, or the tools needed to complete the task.

High-strength steel	High-strength steel boasts exceptional durability, making it the preferred material for automotive aftermarket parts companies manufacturing safety components. It can withstand extreme conditions, ensuring that components made from this material make a significant contribution to vehicle safety. In metalworking services, using lower-gauge high-strength steel allows for the creation of stronger and more durable panels.
Advanced High Strength Steel (AHSS)	Advanced high-strength steel (AHSS) offers advantages such as higher strength and lighter weight, improving fuel efficiency without compromising safety. Its application is crucial for the new energy vehicle modification industry, as balancing weight and durability is paramount. Panels manufactured using AHHS can be made with thinner gauges without sacrificing structural integrity. This highlights the importance of selecting the appropriate gauge for your project.
Aluminum	Aluminum is highly valued for its lightweight and corrosion resistance, which improves fuel economy and overall vehicle performance. Its manufacturing applications are wide-ranging, from 20-gauge aluminum sheets for body panels to thicker sheets for structural components. This makes it an indispensable material in the manufacture of sheet metal modification parts for new energy vehicles .
Magnesium alloy	Magnesium alloys have a strength-to-weight ratio even higher than aluminum, pushing the boundaries of traditional automotive design and performance. Using magnesium alloys allows for the creation of lighter, more powerful modified vehicles. Understanding the nuances of specifications and manufacturing processes is key to maximizing the advantages of these materials when manufacturing parts from both materials .
Titanium	Titanium is renowned for its exceptional strength, lightweight, and corrosion resistance, and is often used as a primary material in the modification of high-performance and luxury vehicles. The use of titanium requires specialized tools to process, highlighting the crucial role of expertise in handling such advanced materials. Despite its higher cost, titanium’s advantages in critical components justify the investment for users seeking ultimate performance and durability.
Carbon fiber reinforced polymer (CFRP)	Carbon fiber reinforced polymer (CFRP) is revolutionizing the automotive industry with its unparalleled strength and lightweight properties. This material is ideal for manufacturing high-performance vehicles and aftermarket parts , as every kilogram of weight reduction can improve a vehicle’s speed and efficiency. Manufacturing CFRP components requires precise processes and extensive experience to ensure that each part maximizes the vehicle’s performance potential.
Stainless steel	Stainless steel is widely used due to its excellent corrosion resistance, primarily in exhaust systems and trim pieces. Its durability makes it suitable for components requiring both longevity and aesthetics. For lower-spec exhaust pipes or 20-gauge trim panels, the versatility of stainless steel makes it indispensable in the automotive industry, highlighting the importance of tailored metalworking services to the specific needs of each project.

Factors affecting the manufacturing cost of automotive aftermarket sheet metal parts

When estimating the manufacturing cost of sheet metal parts for automotive modifications , several factors are particularly important, as these factors will directly affect the project’s economics and final cost.

Material costs	Material costs account for a large portion of the total cost in automotive modification sheet metal parts processing projects . The costs vary significantly between different materials; for example, stainless steel, aluminum alloy, and carbon steel all have different prices.
Processing	Different sheet metal processing techniques affect costs. For example, the complexity and time required for processes such as stamping, welding, and cutting will all affect costs.
Equipment costs	The investment costs of equipment, machinery, and tools required for sheet metal manufacturing are also a significant factor affecting costs. Advanced equipment and tools may increase productivity, but they will also increase costs.
Labor costs	Labor costs are a significant component of sheet metal processing costs, including wages, training, and benefits for operators, technicians, and managers.
Design Requirements	The design requirements of a product directly affect the difficulty and cost of manufacturing. Complex designs require more manufacturing technology and precision, thus increasing costs.
Purchase Quantity	Mass production can typically reduce costs because of sheet metal materials, which can save on labor and equipment through economies of scale.
Quality requirements	High-quality products typically require more stringent process requirements and inspection standards, which may increase costs.

How to estimate the manufacturing cost of automotive aftermarket sheet metal parts

In today’s highly competitive market, a comprehensive understanding of the cost structure of automotive aftermarket sheet metal parts manufacturing is a crucial foundation for establishing appropriate pricing strategies. The production cycle of sheet metal parts covers all critical stages , therefore, the following cost calculation methods are generally used .

Estimate raw material costs	We need to break down the entire production cycle into several manageable units and estimate these units one by one to more accurately estimate the costs associated with each stage. Based on this, our focus should be on calculating raw material costs. Considering product volume, material density, and specific material costs, we can estimate raw material costs using the following formula:Raw material cost = Volumetric material density material cost (per kilogram)
Machining costs	Considering the machine’s hourly cost, cycle time, and system processing efficiency, we cannot ignore processing costs. The formula for calculating processing costs is:Efficiency / (cost per hour per unit cycle time) = Processing cost
Total cost	Adding raw material costs and processing costs yields the total direct production cost. By repeatedly calculating this process at different stages of production, we can fully grasp the cost structure of the entire production cycle, providing a solid foundation for developing effective cost and economic strategies. This detailed cost estimation plays a crucial role in developing sustainable manufacturing plans and pricing strategies.

Your trusted automotive body panel parts manufacturing and design company

At Elimold , we are not only proficient in various automotive aftermarket sheet metal parts manufacturing processes , but we also have a professional technical team that can provide leading parts design services and manufacture high-quality parts for you at highly competitive prices. As an ISO 9001:2015 certified company, we focus on building a quality management system to provide reliable services to our customers.

Our team of experts has experience performing Design for Manufacturability ( DFM ) analyses to improve your designs. We are not just a manufacturer, but also a partner, committed to providing comprehensive support and expert advice to our clients to ensure that designs reduce manufacturing costs while still meeting high-quality standards.

If you have a design model that needs to be manufactured, please send it to us immediately, and we will provide you with a quote right away. Choose Elimold , choose a high-quality, technically advanced, and cost-effective sheet metal manufacturing partner, and let us work together to create superior parts for your projects and achieve greater success.

Conclusion

In the manufacturing of sheet metal parts for new energy vehicles, various processes and materials mentioned in this article are commonly used to meet the design and durability requirements of different car brands , while also satisfying the needs of the markets served by the companies . Based on my years of experience in the industry, most automotive aftermarket sheet metal parts commonly use materials with thicknesses ranging from 16 to the more flexible 18 to 22, balancing strength and flexibility. Repair patches typically use 18 -gauge material to ensure durability and ease of handling.

This diversity makes it possible to manufacture high-quality parts that meet the modification and repair needs of different vehicle brands and different customer groups . The key lies in experience in processing and manufacturing automotive sheet metal modification parts ; choosing a company with extensive experience in manufacturing automotive modification and repair sheet metal parts is crucial to achieving the goal of producing high-quality automotive sheet metal parts . Contact us today for solutions that embody innovation and quality in automotive sheet metal manufacturing.

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