What is the typical cycle time and lead time for automotive cooling plate production?
What Is the Typical Cycle Time and Lead Time for Automotive Cooling Plate Production?
Overview of Cooling Plate Production Timelines
Automotive cooling plates—used in EV battery packs, inverters, and power electronics—require high thermal conductivity, dimensional accuracy, and sealed internal channels. At Neway Die Casting, production timelines are optimized for both prototyping and mass production using high-performance alloys such as A380 aluminum or C12200 copper. Lead times vary based on volume, complexity, and finishing needs.
Typical Die Casting Cycle Time
For high-pressure die casting of aluminum or copper cooling plates:
Cycle time per part:
Simple plates: 40–60 seconds
Complex internal channels: 60–90 seconds
Cycle time includes injection, cooling, ejection, and part removal
Cooling optimization and automated extraction minimize variation and increase productivity
Standard Production Lead Time
Production Stage | Typical Timeframe | Description |
|---|---|---|
Tooling Fabrication | 3–4 weeks | Tool and die making with core insert systems |
Initial Sample & Tuning | 5–7 working days | Includes test shots, flow tuning, and dimensional checks |
Die Casting & Pre-Machining | 1–2 weeks (low volume) | Casting in batches; high-volume lines run daily |
Post-Machining & Surface Finish | 3–5 working days | Milling of ports, sealing faces, and surface treatments |
Leak & Pressure Testing | 2–3 days | 100% batch verification via air or water pressure tests |
Prototype delivery: 2–4 weeks depending on material and finish
Mass production launch: 5–7 weeks from design approval
Volume and Complexity Considerations
Low-volume or pilot runs (100–500 pcs): ~3–4 weeks
Full-scale production (10,000+ pcs): Cycle optimized for daily output of 500–1,200 pcs per die cavity, depending on part size
Complex parts with multiple ports or multi-zone cooling: May require dual-shot tooling or additional machining steps, adding 1–2 weeks
Compliance and Validation
All cooling plates undergo:
ISO 2768-f dimensional inspection
Pressure leak testing (up to 5 MPa)
Thermal path integrity validation
Surface roughness control for sealing zones (Ra ≤ 1.6 µm)
Customer-Oriented Cooling Plate Services
Neway Die Casting offers a complete suite of services for automotive cooling plate production:
Aluminum and Copper Die Casting: Thermal-grade casting with internal flow paths
Post-Machining Services: Port drilling, sealing face milling, and precision surface control
Rapid Prototyping: Quick-turn sample production before full-scale tooling
