EV Charging Station Components Project

Project overview

EV charging hardware is outdoor electrical equipment: the housing has to survive sun, rain and temperature swings while meeting flame-retardancy rules, and the connector gun is handled thousands of times a year in winter gloves. This project covers both the charging pile housing and the charging connector for a new-energy infrastructure program.

Both parts are tooled and molded at our Chang’an, Dongguan factory within the new-energy program family that already includes EV battery trays.

The challenge: two parts, one material story

The pile housing needs weatherable PC/ABS with UV stabilization, UL94 V-0 verification on finished parts, and flat sealing surfaces for the IP-rated enclosure. The connector gun needs a rigid PA-type body with an overmolded soft grip that stays grippable at -30 °C and resists cable-flex wear at the strain relief.

• Housing: flame rating, UV stability and IP sealing verified on finished parts.
• Gun: mechanical TPE anchors, strain-relief geometry that survives flex testing.
• Both parts colored to the customer’s brand standard with masterbatch, batch after batch.

Mold design and build

The housing tool uses simulation-planned gating to keep weld lines out of the display window and connector bay, with its own cooling on the sealing band for flatness control. The gun body is a two-shot tool: rigid shell first, TPE grip and strain-relief ribs overmolded with mechanical anchors so the grip cannot shift or peel in service.

The connector gun’s overmolded grip is anchored through the rigid shell, not glued.

Production and quality control

Housing flatness is CMM-sampled on the sealing band; color is checked against a signed master for both parts. Finished housings pass the customer’s IP water test on a lot plan. Gun grips are peel-checked and the strain relief is validated by the customer’s cable-flex rig on sampled lots. As with all new-energy programs, first-article reports and material certificates ship with each batch.

Results

Both parts passed the customer’s validation: flame rating on finished housings, IP sealing, drop protocol on the gun, and cable-flex life at the strain relief. The tools are running serial volume for the infrastructure rollout, with color consistency holding across lots.

Related: our new energy and EV capabilities, two-shot molding for the connector grip, and the lead time guide if you are scheduling an infrastructure rollout. For quotes, send your files — most are returned within 24 hours.