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🇸🇪 SE Swedish Electric Truck Startup | Lightweight CNC Components for Power Module Prototype

Project Background

In early 2024, we received a collaboration request from a Swedish electric truck startup focused on developing next-generation logistics vehicles for the extreme Nordic climate. At the time, they were in the prototype development phase of their first-generation power module.
To meet the functional demands of their new model, the client urgently required a batch of metal structural parts with high strength, lightweight design, and excellent thermal performance. They were also looking for a manufacturing partner capable of rapid prototyping and flexible production to match their tight R&D schedule.
Through an internal recommendation, the client reached out to us and clearly defined their technical goals:
Achieve a 20%+ weight reduction through optimized part design
Ensure mechanical stability at -30°C operating temperature
Integrate multi-functional features (support, thermal conduction, and structural connection) into a single module
Maintain process consistency for future low-volume production runs

Client Requirements

To support the prototype build of their power module, the client specified the following engineering requirements

Material

Processing Method

Tolerance

Surface Treatment

Sample Lead Time

Quantity

Inspection

Aluminum alloy EN AW-6082 T6 (optimized for strength-to-weight ratio)

5-axis CNC milling, suitable for complex asymmetric housings

±0.01 mm on critical structural features

 Natural anodizing, with specific areas requiring Ra ≤ 1.6 μm to support thermal coating

 Delivery required within 20 calendar days after design confirmation

20 pcs (initial prototype batch)

100% CMM inspection on all critical dimensions, plus functional and assembly verification records

Key Technical Challenges

Lightweight Optimization within Structural Limits
The parts needed to be 20% lighter than the original design while maintaining structural integrity. This called for localized wall thickness reduction without compromising strength.

Dimensional Stability at -30°C
Components had to maintain shape and mechanical properties in extreme cold. Material choice and stress-relief strategies were critical.

Complex Internal Cavities and Thin-Wall Features
The intricate housing design included deep internal structures and thin ribs, requiring high-precision machining and deformation control.

Multi-Functional Integration (Mounting + Heat Dissipation + Structural Support)
Several functional zones needed to be integrated into a single unit, increasing both design and manufacturing complexity.

Tight Turnaround with High Precision
All components had to be fully machined, inspected, and shipped internationally within 20 days—demanding seamless coordination across teams.

Challenges & Solutions

Our Solution

To tackle these challenges, we deployed a comprehensive approach that integrated structural optimization, advanced machining strategies, and efficient project execution

Our engineering team reviewed the client’s CAD models and performed stress analysis to optimize wall thickness without compromising load-bearing capacity.
We added targeted reinforcement ribs in high-stress areas to balance strength and weight.

We selected EN AW-6082 T6 aluminum, well-known for its mechanical stability in sub-zero environments.
A multi-stage stress-relief process was implemented (rough machining → intermediate tempering → final machining) to minimize deformation risks caused by thermal contraction.

We adopted a full 5-axis CNC strategy to accurately process the complex cavity geometry and avoid tool interference common in 3-axis setups.
Custom fixtures and machining paths were designed to allow light, multiple-pass cutting, minimizing tool pressure and preventing deformation in thin-walled areas.

Machining workflows were divided by functional zones (mounting points, heat-conductive surfaces, structural ribs), each with tailored toolpaths and finishing settings.
This allowed us to control tight tolerances, ensure flatness and surface roughness, and maximize the integration of all features in one part.

Machining workflows were divided by functional zones (mounting points, heat-conductive surfaces, structural ribs), each with tailored toolpaths and finishing settings.
This allowed us to control tight tolerances, ensure flatness and surface roughness, and maximize the integration of all features in one part.

We provided full quality documentation (CMM report, material certs, and functional test data), and used custom foam packaging for safe international transit.

Knut
Knut Chief Engineer, Swedish EV Startup
“Excellent collaboration and precision. Your team’s proactive suggestions helped us optimize our design, and the quality of the delivered parts is outstanding.”

Future Collaboration

Two weeks after prototype approval, the client placed a small-batch order of 350 units, delivered in three separate batches. Their engineering team worked closely with us to align on traceability, documentation, and labeling. Together, we standardized batch structures and set up regular check-ins to stay ahead of potential issues.

After three successful deliveries with no major quality concerns, client satisfaction remains strong. We’ve since been invited to support two upcoming platform projects, with technical discussions scheduled for next quarter—marking the start of a deeper, long-term collaboration.

The client especially recognized our strengths in

Deep understanding of functional needs and design cooperation
Technical support in structural optimization and process design
Ability to deliver high-precision parts within a compressed timeline
The project has since progressed to beta vehicle prototyping, with low-volume production expected to begin later this year.

Project Summary

This wasn’t just a machining job for us—it was a true collaborative effort with the client’s R&D team. The requirements were clear and demanding, pushing us to think beyond machining: from lightweight and thermal performance to precision under harsh conditions.
We didn’t just follow the drawings—we worked to understand how these parts functioned inside the system. We proposed improvements, adjusted the process under time pressure, and made sure quality was never compromised.
This project reaffirmed what we always strive to be: not just a manufacturer, but a hands-on engineering partner who solves problems and helps our clients bring their innovations to life.

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JoeVin

Joe Vin is the Operations Director at Alec Model, a CNC machining and 3D printing manufacturer in China. With full in-house production and years of hands-on experience, he helps global clients solve real-world manufacturing challenges — from prototyping to production.

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