Injection Molding Machines for E-Mobility – HV Component Production 2025

Introduction to Injection Molding Machines for E-Mobility

The global electric vehicle market is forcing manufacturers to redesign entire injection molding cells. Injection molding machines handling battery components, high-voltage connectors, and BMS housings must combine the highest precision, process cleanliness, and full quality traceability. With production volumes in the millions and OEM requirements for ISO 21434, Automotive SPICE, or PPAP Level 4 m, the margin for error is minimal. This article shows how to design a line that integrates all-electric and hybrid injection molding machines, smart molds, and MES traceability.

TEDESolutions partners with EV manufacturers to launch automated cells for HV connectors, battery modules, and cleanliness-sensitive components. This guide will help you understand the key machine features, critical parameters for electrical safety, and how to set up inline quality control.

Rising requirements also apply to sustainability. Fleet owners demand carbon footprint declarations, so injection molding machines must offer energy recuperation and integration with media management systems. In practice, this means using servo drives with regenerative braking energy recovery, monitoring CO₂ emissions per cycle, and communicating with ESG platforms. Without this data, many manufacturers won't achieve homologation in EU and US markets.

Another factor is shortening the EV program time-to-market (SOP). Factories need modular cells that can be relocated to another country in just a few weeks. That's why the new generation of injection molding cells is built on standard base frames, with automation and injection molding machines designed for quick changeovers to other part references.

What Is an E-Mobility Injection Molding Machine?

An e-mobility injection molding machine is an injection molding machine configured for technical materials (PBT, PA6/PA66, PPS, LCP) used in HV connectors, insulators, and battery modules. The process includes plasticizing granules, rapid injection, and holding pressure in precision molds with built-in temperature and surface conductivity sensors. Surge protection systems and contamination monitoring are required to meet UL 94 V-0 and IEC 60664 standards.

Modern systems use closed-loop screw speed control, active hot runner nozzles, and SPC modules collecting data from 20+ signals per cycle. This enables injection molding machines to achieve dimensional repeatability of ±0,01 mm for thin-wall connectors and minimize stress cracking risks during battery operation.

E-mobility-dedicated machines also feature advanced operator interfaces. The HMI panel displays cycle energy maps, robot integration status, and quality alerts from the vision system. Operators can access documentation for a specific part number with one click, significantly speeding up audits. These solutions are compatible with OEM cybersecurity, including network segmentation and digital recipe signing.

Increasingly popular are injection molding machines with integrated cleanrooms at ISO 7. The entire mold area is enclosed with laminar airflow and particle control, eliminating contaminants on HV insulators. The modular design allows expanding the cleanroom with additional assembly stations without interrupting production.

History of HV Component Injection Molding Development

The first high-voltage components for hybrid vehicles were produced on conventional hydraulic injection molding machines. From 2005–2010, prototype projects focused on material thermal resistance. The revolution came after BEV platforms launched in 2013. OEMs began requiring batch traceability and cleanliness monitoring, driving migration to all-electric injection molding machines with mold area encapsulation.

Between 2016 and 2020, EV lines underwent transformation: integration with MES/MOM, automatic copper insert screwing, collaborative robots applying FIPG seals. Today, we're seeing the fourth generation of solutions, where hybrid injection molding machines combine hydraulic power (clamping) with servo drives (injection) to reduce cycle times below 20 s. Large gigafactories also design cells with redundancy for reliable HV connector supply.

In the coming years, digital twins of cells are expected to become widespread. EV manufacturers will test material changes or new connector geometries in virtual environments without halting production. Tederic and TEDESolutions are already implementing models that analyze cooling temperature effects on contact resistance and predict mold failures.

The history of e-mobility injection molding is also the history of data security standardization. After cyberattacks at several gigafactories in 2021, OEMs mandated OT network segmentation. Injection molding machines must now support TLS encryption and certificate-based authentication, fundamentally changing machine builders' approaches to control software.

Types of Injection Molding Machines in E-Mobility

Drive technology selection depends on the application. Hydraulic injection molding machines excel with thick-wall structural composites requiring very high clamping force. All-electric machines dominate connector and thin-wall part production, offering motion repeatability and clean workspaces. Hybrids strike a balance—using servo drives for injection and hydraulics for clamping to handle larger gates while maintaining precision.

Equally important is equipping machines with traceability systems: capacitive sensors for copper insert presence, in-mold vision cameras, and integration with OCV (Open Circuit Voltage) safety systems. This makes the cell part of the larger EV factory ecosystem.

Dual-injection-unit injection molding machines are also gaining popularity, enabling two-material injection in one cycle without a rotary table. For battery applications, this combines PBT insulation with TPE sealing and reduces assembly operations. Users appreciate independent control of the two screws, boosting flexibility for short-run EV models.

Another trend is adapting machines for vacuum or inert gas environments. For oxidation-sensitive HV components, nitrogen enclosures surround the mold. All-electric injection molding machines integrate vacuum valve control and gas recovery systems to maintain consistent conditions regardless of ambient temperature.

Injection Molding Machines for HV Connectors

All-electric injection molding machines from 180–350 tons handle most HV connectors. High injection dynamics (over 400 mm/s) fill micro-ribs ensuring IP6K9K sealing. Special sequential hot runner nozzles enable uniform cascade filling. A SCARA robot works with the machine to insert Cu pins and FKM seals, while the control system logs every part in the traceability database.

Advantages:

• Screw motion precision – minimizes micro-cracks in insulation.
• Process cleanliness – no oil in the mold area meets electrical cleanliness standards.
• Low noise – allows installation near battery assembly lines.

Challenges:

• High CAPEX – machine and mold costs are many times higher than in traditional cells.
• Temperature management – thin walls demand fast-response temperature control.
• IT integration – must support OPC UA and cybersecurity.

Compatibility with HV test systems is also key. Cells are increasingly equipped with hipot stations testing each connector at 1500 V. The injection molding machine must provide cycle data to the tester controller to link results with mold and cell numbers. Without this integration, passing OEM audits is difficult.

Battery Module Production Lines

Module components (frames, covers) are produced on hybrid injection molding machines with 650–900 tons of clamping force. Glass or carbon fiber-reinforced materials increase demands on mixing and screw wear resistance. Cells often include two-material injection—e.g., PP+GF structure plus TPE seal. Machines feature rotary tables and servo swing nozzles to handle 2K injection in one cycle.

Thermal distortion control is critical. The MES system monitors mold deflections via FBG sensors, with data feeding into an SPC module for trend analysis. This enables early detection of planarity issues in module-to-cell mating.

Manufacturers are pushing for battery weight reduction, increasingly using polyamide- and carbon fiber-based composites. These abrasive materials require protected barrels and nozzles, so the injection molding machine must have hardened liners and nozzles. Mold degassing systems are also essential to remove air and volatiles, preventing porosity. Rotary table control is synchronized with a robot that places cooling inserts and FIPG seals.

BMS Housings and Power Electronics

BMS and inverter housings require thin walls, EMC shielding, and temperatures up to 125 °C. All-electric injection molding machines from 120–220 tons offer the highest precision here. Molds include aluminum insert overmolding, requiring 6-axis robot integration and pre-clamp insert temperature control (pyrometer). Some designs use two-platen injection molding machines for greater opening stroke to accommodate sensors and shielded cables.

Software packages with IPC-2221 recipe libraries and automatic PPAP report generation are becoming standard. This cuts qualification time for new components by quality engineers.

EMI shielding is also growing in importance. More projects use conductive coatings applied in-mold or post-process. The injection molding machine must interface with plasma spray modules and ensure precise part positioning. Quality checks include surface resistivity measurements and ESD discharge resistance tests.

Design and Key Components

The e-mobility cavity setup includes more than just the injection molding machine. Essential components include: molds with temperature sensors in critical cavities, hot runner systems with sequencing nozzles, automation for insert feeding, traceability systems, part removal robots, and HV test stations. The entire setup is networked via OT/IT to feed process data into an analytics platform.

Maintaining cleanliness is critical – the cavity is enclosed with laminar flow guards, and H14-class HEPA filters clean the air around the mold. VOC sensors and particle counters are also installed to document surface cleanliness for every batch.

An integral part of the design is the mold management system (Tool Management). It logs cycles, temperatures, alarms, and service history. This allows maintenance planners to track mold loading and schedule overhauls without interrupting production. If needed, the cavity can be relocated to another plant while preserving all settings and documentation.

HV Injection Unit

The injection unit must handle fiber-reinforced materials and conductive additives. It features bimetallic screws, heating zones rated at 12–16 kW, and a servo drive delivering acceleration up to 800 mm/s². Temperature control in each zone has ±1 °C tolerance to minimize material degradation and inclusions in connectors. Sequential nozzles are controlled by needle valves that sync opening with screw position.

Real-time viscosity sensors are increasingly common. Viscometer data feeds into AI algorithms that automatically correlate parameters with deviations in connector electrical measurements. If viscosity exceeds the threshold, the system halts the batch and alerts the shift leader.

The e-mobility injection unit also includes automatic purging systems. After each material change, a purge cycle checks color and conductivity, with waste directed to a closed batch-numbered container. This minimizes the risk of material mix-ups that could compromise insulation.

Clamping Unit and Mold

The clamping unit in EV lines must withstand dynamic temperature changes. Hybrid machines use high-flow hydraulics for uniform holding pressure, while all-electric versions feature column servo drives. Tie-bar deflection compensation is key – linear sensors monitor clamping force distribution in real time and adjust holding pressure to prevent sealeaks.

HV connector molds include copper inserts, cavity pressure sensors, analog temperature signals, and inspection cameras. Data connectors route through IP67 modules for easy mold servicing outside the cavity. The system integrates with tool management to monitor cycle counts and schedule preventive maintenance.

Cooling systems are also critical. Conformally 3D-printed channels deliver coolant precisely to HV insulator hotspots. The mold controller analyzes real-time temperatures and adjusts flow via proportional valves. This ensures tight dimensional tolerances and dielectric stability.

Key Technical Parameters

1. Clamping force (t)

Selected based on part projected area and injection pressure up to 2000 bar. Connectors require 180–250 t, modules up to 900 t. A 10–15% buffer is recommended for seal stability.

2. Injection speed (mm/s)

Critical for thin walls. Modern machines achieve 400–600 mm/s to fill micro-channels and minimize weld lines.

3. Temperature control (°C)

Barrel zones 260–320 °C, nozzles 280–330 °C. ±1 °C stability prevents polymer degradation and dielectric breakdown.

4. Holding pressure (bar)

Monitored in real time, especially for TPE parts. Maintaining holding pressure >70% of nominal until crystallization ends reduces shrinkage.

5. Process monitoring

Requires cavity pressure sensors (Kistler), temperature, screw position, and insert ID sensors. Data is stored in the MES system, which generates PPAP reports.

6. Energy per cycle (kWh)

All-electric machines achieve 0.35–0,5 kWh/cycle for connectors. Hybrids with variable displacement pumps use 15% more but deliver higher clamping force.

7. Automation

e-Mobility cavities require take-out robots (3-axis or 6-axis), 2D/3D vision systems, HV test stations (1500 V hipot), and DPM laser marking.

8. Process stability

Cp and Cpk indices should exceed 1.67 for critical insulation dimensions. SPC systems automatically stop the line when trends approach controlimits. Data is archived and shared with OEM customers via quality portals.

9. Data security

Injection molding machines must support recipe encryption, RFID operator login, and parameter change tracking with electronic signatures. TISAX Level 3 compliance is increasingly required for automotive OEM partnerships.

Applications in e-Mobility

Traction Batteries

Production of HV connectors, LV124 low-voltage plugs, insulating spacers, and module housings. Requires UL 94 V-0 materials, TÜV testing, and ±0,05 mm tolerances.

Charging Stations and Onboard Chargers

Injection molding machines produce CCS sockets, inverter housings, and cooling modules. UV and chemical resistance plus IP55 testing are essential.

Energy Management Systems

BMS housings, current transformer components, and HV box insulation elements. EMC compliance and copper insert integration are key.

Bus and Heavy-Duty Segment

Thick gaskets, structural elements, and battery brackets. Requires high clamping force and thermal warpage control.

Micromobility

Connectors for e-scooters and e-bikes, where low part cost and compact machines under 150 t are prioritized.

Energy Storage Systems (ESS)

This segment is growing as fast as automotive. Injection molding machines produce insulators, busbars, and cooling elements for stationary storage. Requirements include UL 9540A fire resistance and tropical climate operation, making line humidity control standard.

How to Select an Injection Molding Machine for e-Mobility?

1. Part Analysis

• Projected area, flow length, material type, and dielectric requirements.
• Determine clamping force + buffer.
• Define cavity count and hot runner strategy.

2. Total Cost

• Compare TCO of all-electric vs. hybrid machines.
• Factor in mold costs with sensors and automation.
• Analyze energy consumption and heat recovery potential.

3. Automation Architecture

• OPC UA, MQTT compatibility, and IEC 62443 cybersecurity.
• Support for Automotive SPICE recipes and MES/MOM integration.
• Scalability for process AI expansion.

4. Standards and Validation

• ISO 9001, IATF 16949, PPAP, OEM audits.
• IEC 60664 electrical safety, UL 94.
• Single-part traceability.

5. Technology Partner

• 24/7 service and parts availability for gigafactories.
• Support for Moldflow simulations and PPAP validation.
• Experience with insert installation automation in cells.

6. Scalability

• Ability to expand the cell with additional robots or test stations without controller changes.
• Cooling and power capacity headroom for future upgrades.
• Standardized interfaces for faster machine relocation between plants.

Maintenance and Uptime

Uptime management in e-mobility cells requires combining predictive analytics with rigorous quality procedures. Injection molding machines are equipped with vibration, temperature, and screw wear sensors that feed data to the CMMS system. Trend analysis enables scheduling hydraulic valve replacements, HEPA filter changes, or pressure sensor calibrations before any complaints arise.

Work zone cleanliness is checked at every shift change, with weekly hipot tests and part surface resistance measurements. Molds undergo inspection every 50 tys. cycles: cleaning cooling channels, lubricating guides, and checking valve gate needles. Automation requires regular cybersecurity updates, and the traceability system archives data for a minimum of 15 l years in accordance with OEM requirements.

Implementing a Condition-Based Maintenance program is key. Operators log visual and audible defects via a mobile app, and algorithms analyze correlations between symptoms and failures. This approach can reduce planned downtime by up to 30%. Uptime teams also collaborate with material suppliers—data from dryers and feeders helps detect moisture anomalies before they impact connector insulation properties.

Summary

Injection molding of e-mobility components combines the highest quality demands with intense time and cost pressures. The key is a properly configured injection molding machine—all-electric or hybrid—integrated with smart molds, traceability systems, and extensive automation. Component analysis, parameter selection, IT integration, and consistent uptime management determine whether the factory delivers millions of HV connectors without complaints. TEDESolutions supports producers throughout the production cellifecycle: from audit and startup to predictive maintenance, keeping e-mobility lines competitive across future generations of electric vehicles.