Custom Aluminum Die Cast Motor Housing Manufacturer
High-pressure die casting and squeeze casting solutions for custom aluminum motor housings with precision machining, leak testing, and complete in-house manufacturing.
How We Manufacture Aluminum Die Cast Motor Housings
We manufacture aluminum motor housings based on customer drawings and performance requirements.
For conventional high-volume housings with complex geometry and thin walls, high-pressure die casting is typically the preferred process.
For applications requiring higher density, T6 heat treatment, welding, improved mechanical properties, or demanding leak-tightness, squeeze casting can be evaluated as an alternative.
Our engineering review covers alloy selection, casting process, tooling and gating design, machining datums, critical tolerances, and inspection requirements before production begins.Manufacturing Capabilities for Aluminum Motor Housings
| Item | Capability |
| Casting Process | High-Pressure Die Casting (HPDC) / Squeeze Casting for higher performance requirements |
| Aluminum Alloys | ADC12, A380, A356, AlSi10Mg and project-specific alloys |
| Die Casting Machine | Up to 1100T |
| Part Size | Evaluated based on projected area, geometry, and machine tonnage |
| Typical Wall Thickness | From 2 mm, depending on alloy, geometry, and casting process |
| CNC Machining | Tight-tolerance machining for critical bores, datums, and sealing surfaces |
| Leak Testing | Water pressure testing / Helium leak testing |
| Dimensional Inspection | CMM inspection for critical dimensions and machined features |
| Heat Treatment | T5 / T6 depending on alloy and casting process |
| Surface Finishing | Sandblasting, powder coating, painting, e-coating and passivation |
| Tooling | In-house design, manufacturing and DFM support |
| Quality Documentation | PPAP available upon project requirements |
From Drawing to Finished Aluminum Motor Housing
A streamlined manufacturing process for aluminum motor housings, from tooling and casting to machining, testing, and final approval.
01
Drawing Review & DFM
02
Mold Development
03
Trial Casting
04
CNC Machining
05
Quality Inspection
06
PPAP / Approval
07
Mass Production
08
Ready to Ship
Product Description for Die Cast Aluminum Motor Housing
Choosing the Right Casting Process
High-pressure die casting (HPDC) is typically our first choice for high-volume aluminum motor housings with complex geometry, thin walls and demanding dimensional consistency.
For motor housings requiring higher internal density, T6 heat treatment, welding, improved mechanical properties or demanding leak-tightness, we evaluate squeeze casting as a higher-performance alternative.
Choosing the Right Aluminum Alloy
Material selection depends on the casting process and performance requirements of the motor housing.
ADC12 and A380 are commonly used for high-pressure die casting.
For applications requiring T6 heat treatment, higher mechanical properties, welding or improved internal density, alloys such as A356 and AlSi10Mg can be considered together with squeeze casting.
Final alloy selection should be based on the drawing, mechanical requirements, sealing requirements and production volume.Our Die Casting Aluminum Motor Housing Products
- Material: A356+T6
- Process: Low-Pressure Casting
- Unit Weight: 9.5kg
- Annual Volume: 10000 pcs
- Features: extremely lightweight design, excellent heat dissipation, good airtightness
Aluminum EV Motor Housing
- Material: ADC12
- Process: High-Pressure Die Casting
- Unit Weight: 3.8kg
- Annual Volume: 80000 pcs
- Features: high dimensional accuracy, high rigidity, lightweight, IP65–67 protection
Aluminum Servo Motor Housing
- Material: ADC12
- Process: High-Pressure Die Casting
- Unit Weight: 5.5kg
- Annual Volume: 600000 pcs
- Features: high rigidity, good oil sealing performance, noise reduction, lightweight
Aluminum Gear Motor Housing
- Material: A356+T6
- Process: Squeeze Casting
- Unit Weight: 18kg
- Annual Volume: 15000 pcs
- Features: high strength, low porosity, fatigue resistance, reliable structural performance
Aluminum Traction Motor Housing
Why Choose CEX for Aluminum Motor Housing Die Casting?
In-House Tooling & DFM
In-house tooling from DFM and mold flow analysis to mold manufacturing and trial, helping identify casting risks before production.
HPDC + Squeeze Casting
HPDC up to 1100T for conventional production, with squeeze casting available for low-porosity, T6, welding and high-performance requirements.
Casting + CNC Machining
Integrated casting and precision machining with early planning of machining datums, stock allowance and critical dimensions.
Quality Control
CMM,X-ray, material analysis and leak testing are available to verify critical requirements from casting to finished parts.
Auminum Motor Housing Solutions for Demanding Applications
EV Drivetrain System
Typical Parts
Aluminum EV Motor Housings
Key Challenges
• Water-cooling channel leakage due to internal porosity
• Weight reduction vs. structural strength
CEX Casting Engineering Notes
Using Squeeze Casting
High-pressure solidification produces aluminum EV motor housings with high density, near-zero porosity, and excellent airtightness. A356 + T6 further enhances strength, fatigue resistance, and long-term durability for demanding EV applications.
Industrial Automation Line
Typical Parts
• Aluminum Servo Motor Housings
• Aluminum Gear Motor Housings
Key Challenges
Insufficient dimensional accuracy causes errors during motor operation
CEX Casting Engineering Notes
Using High-Pressure Die Casting
HPDC delivers consistent dimensions and supports complex integrated structures for small-sizedmotor housings. CNC machining further improves critical mating surfaces and hole locations for assembly accuracy.
Commercial Vehicles
Typical Parts
Aluminum Traction Motor Housings
Key Challenges
• Low structural strength due to internal porosity and shrinkage
• Vibration and fatigue loads
CEX Casting Engineering Notes
Using Squeeze Casting
Bottom vertical feeding prevents air entrapment in the molten aluminum, and the immense pressure applied during solidification improves casting density and reduces internal porosity. T6 heat treatment further enhances strength and fatigue performance.
FAQs About Die Casting Aluminum Motor Housing
What materials can you use for aluminum motor housings?
ADC12/A380
Thermal Conductivity: 96–100 W/(m·K)
Alloy System: Al-Si-Cu (aluminum-silicon-copper)
Features: Excellent fluidity and strong mold-filling capability; ideal for high-pressure die casting in high-volume, high-speed production of aluminum motor housings; low cost and good dimensional stability.
A356
Thermal Conductivity: 150–170 W/(m·K)
Alloy System: Al-Si-Mg (aluminum-silicon-magnesium system)
Features: Low impurity content; when used in low-pressure casting or squeeze casting, the aluminum motor housings exhibit extremely high internal density and excellent airtightness; after T6 heat treatment, they possess high strength and outstanding fatigue resistance.
AlSi10Mg
Thermal Conductivity: 130–150 W/(m·K)
Alloy System: Al-Si-Mg (aluminum-silicon-magnesium system)
Features: A classic cast aluminum-silicon alloy that balances good fluidity, strength, and corrosion resistance, making it an ideal material for manufacturing complex, integrated water-cooled aluminum motor housings.
Which casting process is best for aluminum motor housings?
There is no “best” casting process; the choice must be based on the dimensions and structure of the aluminum motor housing, process requirements, cost considerations, and other factors.
Currently, the three common casting processes for aluminum motor housings are: high-pressure die casting, low-pressure casting, and squeeze casting.
High-Pressure Die Casting
Suitable for the production of high-volume, small- to medium-sized, low-cost aluminum motor housings.
Common Applications: aluminum servo motor housings, aluminum gear motor housings, aluminum power tool motor housings, etc.
Low-Pressure Casting
Supports the casting of complex internal water-cooling channel structures inside housings and supports T6 heat treatment to enhance housing strength; specifically suited for the production of water-cooled aluminum motor housings for electric vehicles.
Squeeze Casting
Suitable for aluminum motor housings requiring high strength, low porosity, and excellent fatigue resistance. High pressure is applied during solidification to improve casting density and reduce internal porosity.
Common Applications: aluminum traction motor housings, aluminum pump motor housings, etc.
Can you manufacture custom aluminum motor housings from drawings?
Yes, we fully support the customization of aluminum motor housings based on your drawings.
We specialize in the manufacture of aluminum motor housings and offer high-pressure die casting, low-pressure casting, gravity casting, squeeze casting, and CNC machining services. Simply provide us with your 2D and 3D drawings and technical requirements; our engineers will evaluate the appropriate casting process, mold costs, unit price of castings, unit price of casting machining, and lead time for you.
Click “Contact Us” today to get a free and quick quote!
What machining tolerances can you achieve for aluminum motor housings?
We are capable of achieving micrometer-level precision tolerances. The specific key specifications are as follows:
| Inspection Items | Typical Control Tolerance Range | Applicable Areas |
| Dimensional Tolerances | ±0.005mm | Bearing Bore, Bearing Seat, Critical Mating Surfaces |
| Concentricity | ≤0.008mm | Stator Cavity, Front/Rear End Cover Bearing Bores |
| Runout | ≤0.01mm | Mounting Flange Surface, Register End Face |
| Flatness | ≤0.02mm | Mating Surface, Water-Cooling Cover Sealing Surfaces |
How do you control porosity in cast aluminum motor housings?
CEX Casting minimizes porosity in aluminum motor housings through four key steps:
1. Centralized melting of raw materials, combined with rotary degassing, to remove excess gases and impurities
2. 3D software simulation of filling during the mold design phase to optimize venting and runner designs, thereby preventing gas entrapment during actual pouring
3. Specialized casting techniques, such as low-pressure casting, which ensures smooth filling from the bottom up; or squeeze casting, which applies bottom vertical feeding to prevent air entrapment in the molten aluminum, and the immense pressure applied during solidification to reduce internal porosity.
4. If porosity persists, a vacuum impregnation process can be performed to fill the pores with resin, ensuring there are no leakage issues.
Can you perform leak testing on aluminum motor housings?
Yes, in accordance with customer requirements, we perform leakage testing on aluminum motor housings.
We use the following two methods:
Water Test: After filling the housing with dry air at a specified pressure, it is submerged in a water tank to observe whether any bubbles form. This method is suitable for testing mid- to low-end housings.
Helium Leak Test: For high-end aluminum motor housings, a helium leak detector is used to perform high-precision leak detection, with a detection accuracy of up to 9.8 × 10⁻¹⁰ mbar·L/s.
What is the difference between die casting and squeeze casting for aluminum motor housings?
The main differences between die casting and squeeze casting lie in the filling method, solidification pressure, and the internal density of the castings.
Process Differences
Die casting uses high-speed turbulent filling, which is highly efficient but prone to internal porosity; squeeze casting uses low-speed laminar filling and solidifies under ultra-high pressure, resulting in a dense, porosity-free microstructure that supports T6 heat treatment.
Impact on Aluminum Motor Housings
Air Tightness: Water-cooled motor housings have extremely stringent requirements for leak prevention. Since squeeze casting produces virtually no internal porosity, its airtightness far exceeds that of die casting, effectively eliminating the risk of coolant leakage.
Mechanical Strength: Squeeze casting motor housings can undergo T6 heat treatment, resulting in tensile strength, yield strength, elongation, and hardness that are all higher than those of die casting motor housings.
Cost: Die casting is better suited for producing complex housings with thin walls and in very high volumes, resulting in a lower cost per unit.
Summary
For motor housings requiring integrated water-cooling channels, high airtightness, or high mechanical performance, squeeze casting is more suitable; for standard motor housings with thin walls, complex shapes, high production volumes, and cost-sensitive requirements, die casting is more suitable.
What is the difference between low-pressure casting and high-pressure die casting for aluminum motor housings?
The key differences between low-pressure casting and high-pressure die casting lie in filling speed, internal density, and compatibility with complex cooling channels (sand cores), which directly determine the airtightness and structural design of motor housings:
Key Process Differences
Low-pressure casting employs a steady, low-speed filling process, resulting in a dense microstructure free of entrapped air, and supports T6 heat treatment and the use of sand cores; High-pressure die casting employs extremely high-speed filling, resulting in very fast production cycles, but is prone to microscopic porosity and cannot use sand cores.
Specific Impacts on Motor Housings
Cooling Channel Design and Airtightness: Low-pressure die casting supports sand cores, allowing for the direct casting of complex, integrated 3D water-cooling channels, and offers excellent airtightness to prevent coolant leakage; HPDC cannot use sand cores; cooling channels are typically open (requiring post-cast sealing), and the water-cooled walls are prone to leakage risks due to porosity.
Strength and Wall Thickness: Low-pressure die casting is suitable for medium- to thick-walled housings, offering higher strength and toughness after T6 heat treatment; high-pressure die casting is suitable for lightweight housings with wall thicknesses of 2–4 mm.
Summary
Low-pressure casting should be selected for aluminum motor housings with complex three-dimensional water-cooling channels, high airtightness requirements, or high-performance demands; high-pressure die casting should be selected for general-purpose motor housings with thin walls, high-volume production, and low unit costs.
How can you reduce the cost of custom aluminum motor housings?
The cost of custom aluminum alloy motor housings can be reduced through the following measures:
Optimize DFM
Simplify the geometry of the aluminum motor housing, standardize draft angles (typically ≥ 1.5°) and chamfer radii, and minimize EDM machining and complex core-pulling structures.
Maintain uniform wall thickness (recommended 2.5–4 mm) to avoid localized over-thickness, which can cause shrinkage cavities or excessively increase material weight and cooling time.
Select the Appropriate Casting Process
High-Volume Production (>10,000 Units): Use high-pressure die casting, which offers high production efficiency, the lowest unit cost, and good dimensional stability.
Small to Medium Batches/Complex Cooling Channels (<5,000 Pieces): Use low-pressure casting, which requires significantly less mold investment than high-pressure die casting and enables integrated water-cooling channels via sand cores.
Minimize Post-Casting Machining
Reserve only the necessary machining allowances (1–2 mm) on critical mating surfaces and hole locations; retain the as-cast surface directly on non-mating surfaces.
Optimize Cooling Channels and Sealing Solutions
When using high-pressure die casting, design with open cooling channels and cover plates whenever possible to avoid costly secondary machining or excessively high infiltration rates for leak prevention.
Use Common Materials
Prioritize commonly available grades on the market, such as A380, ADC12, A356, and AlSi10Mg, to reduce material procurement costs.
How do you ensure the aluminum motor housing fits the motor assembly?
Ensuring a precise fit between the aluminum motor housing and the motor assembly hinges on the following key aspects:
Precision Machining of Critical Mating Surfaces
CNC precision machining of the bearing chamber and stator flange to control dimensional and coaxiality tolerances to the micrometer level (typically ≤0.03 mm) to prevent vibration and abnormal noise.
Optimal Interference Fit Design
Carefully calculate the difference in thermal expansion between the aluminum motor housing and the steel stator/bearings, determine the precise interference fit, and use hot-shrink or cold-shrink assembly processes to ensure no loosening occurs across the entire temperature range.
Stress Relief to Prevent Deformation
Perform stress-relief annealing or aging treatment to prevent housing deformation after assembly caused by residual stresses from casting and machining.
CMM and Mock-Up Assembly
Use a coordinate measuring machine (CMM) to perform 100% inspection of the first unit’s critical geometric tolerances, and conduct a stator mock-up assembly verification prior to mass production.