EV Battery Cooling Tube Production

Precision Fabrication Equipment for Electric Vehicle Cooling Systems

Electric vehicle (EV) thermal management demands a completely different approach to tube fabrication compared to traditional internal combustion engines. Battery cooling plates, snake tubes, and chiller lines require ultra-thin walls, complex multi-radius geometries, and 100% leak-free reliability to ensure battery safety and vehicle longevity.

The Technical Demands of EV Thermal Lines

· Ultra-Thin Aluminum Processing: Most EV cooling channels use specialized aluminum alloys (like 3000 or 6000 series) with wall thicknesses often under 1mm. These tear or collapse easily under standard bending forces.

· Complex Multi-Radius Geometries: Snake tubes must wind perfectly around battery cell modules, requiring continuous, smooth, multi-radius bending without stopping.

· Internal Cleanliness: Any contamination or inner wall scratching during the fabrication process can restrict coolant flow or cause blockages.

The Wonsten Technical Approach

Specialized EV Cooling Tube Benders

We have engineered a specific line of high-precision, small-radius CNC benders optimized for thin-walled aluminum tubing.

· Left and Right Bending in One Cycle: Our machines can switch bending directions (clockwise and counter-clockwise) automatically within the same program, allowing you to run complex snake tubes without taking the part out of the machine.

· Scratch-Free Tooling: We utilize customized wiper dies and specialized mandrel coatings to eliminate internal and external surface marking, preserving the structural integrity of the aluminum.

Precision Aluminum Extrusion Lines

To feed your cooling tube production, Wonsten provides high-stability aluminum extrusion machines capable of producing multi-hollow profiles and micro-channel flat tubes with high dimensional consistency.