Scalable metal manufacturing for electrical and energy applications

When small design decisions define long-term competitiveness

Electrical manufacturers are under pressure from every direction.

Products are becoming more compact and integrated. Safety and compliance requirements are tightening. Sustainability targets are no longer optional. At the same time, production volumes must scale reliably without adding cost, risk or supply chain complexity.

In this environment, small metal design and manufacturing decisions often determine long-term competitiveness. In this environment, small metal design and manufacturing decisions often determine long-term competitiveness. What may look like a minor geometry change, a material optimization, or replacing three assembled parts with one deep drawn structure, can significantly affect cost, performance and scalability.

From component thinking to serial production thinking

Components for electrical devices, power distribution systems and battery applications are not just metal parts. They must perform consistently under electrical, mechanical and thermal loads, not only in prototypes but across thousands of units in serial production.

This means meeting strict requirements related to:

• safety and regulatory compliance
• dimensional accuracy and repeatability
• long service life
• scalable mid- and high-volume production

The real challenge is not only meeting specifications. It is designing products that remain reliable and stable when production scales.

Consistent performance at scale requires repeatable forming processes, controlled material selection and well-structured assembly. These capabilities form the foundation for predictable quality and reliable lead times in switchgear structures and other power distribution components.

 
The same manufacturing expertise is increasingly applied in battery modules and energy storage systems, where lightweight structures, structural supports and cooling-related sheet metal components are critical for both performance and sustainability.

When manufacturing expertise is involved early, structural improvements become possible. The outcome varies by product and design, but across different projects our customers have achieved:

• up to 75 % annual raw material cost savings through design and material optimization
• material thickness reductions of up to 60 % without compromising strength
• CO₂ emission reductions of up to 14,100 kg per year in a single component
• simplified assemblies replacing multiple parts with one deep drawn part
• production transfers completed in 6 months, improving delivery performance by over 20%
• rapid prototyping in as little as 4 days

What we manufacture for electrical and energy industry applications?

Here are some examples we are working with:

• stamped and deep-drawn sheet metal components
• precision springs and wire forms for contact, locking and switching functions
• copper and aluminium busbars and conductor components
• protective and decorative covers with controlled surface quality
• structural supports and mounting elements with integrated formed geometries
• complete assemblies combining metal forming, spring manufacturing and assembly

Production is engineered for scalable serial manufacturing, supported by in-house tooling expertise and coordinated documentation and logistics.

Manufacturing as a strategic lever

Long-term cooperation with leading electrical manufacturers demonstrates a clear pattern:
The most successful projects start before production begins.

When manufacturing expertise is integrated early in the design phase, electrical manufacturers gain:

• faster time-to-market
• lower structural cost
• improved sustainability metrics
• greater confidence in serial ramp-up

In complex electrical products, manufacturing is a competitive advantage.

Interested in how integrated metal manufacturing can support your next electrical project?

Download our brochure or contact our team to continue the discussion.