Case Study: Custom Cold Headed Fasteners for EV Battery Pack
Learn how Taily Metal delivered high-strength, non-standard cold headed fasteners for a leading EV battery manufacturer, reducing costs by 35%.
The Challenge
A leading Tier 1 automotive supplier approached Taily Metal with a critical requirement for a new electric vehicle (EV) battery pack assembly. The project demanded a custom-designed, non-standard bolt that could provide both structural integrity (Grade 10.9) and high corrosion resistance for a service life exceeding 15 years.
The Taily Metal Solution
Initially, the client considered CNC machining due to the complex head geometry. However, our engineering team proposed a multi-station cold heading process. By optimizing the die design, we were able to form the complex head shape in a single operation, maintaining grain flow and fatigue resistance.
Cost and Efficiency Impact
The cold heading process delivered a 35% reduction in unit cost compared to CNC machining and reduced material waste from 40% to less than 2%.
The Result
Functional samples were delivered in 10 days, passing all mechanical tests. The final production run of 500,000 units was delivered ahead of schedule.
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