What EV and battery packs need from wireforms
The application sets the requirement: cell interconnects, fusing, isolation, vibration and thermal cycling. A part that works on a bench can fail in service if the thermal cycle, vibration, cleaning or fault current is not in the drawing review.
Typical parts in this category include clips, springs, contacts, cages and brackets. We review the mating part and the assembly context, not only the standalone drawing.
Design and process fit
The main processes are CNC wire forming, four-slide forming, welding and assembly. The process choice follows the geometry, the volume and the tolerance. A prototype may use a different route from production, but the drawing should be designed for the final process.
Materials include music wire, 302 and 316 stainless, phosphor bronze and beryllium copper. The grade, temper and finish must match the duty. For EV and battery packs, the design review should also cover creepage, clearances, thermal paths and service access where they apply.
Quality and test evidence
Inspection covers wire diameter, bend positions, leg angles, load at length and plating thickness. Depending on the programme, the evidence can include pull, weld shear, thermal cycling and insulation. The first article should show the characteristics that matter to the assembly, not every dimension at the same weight.
Standards that may apply include IATF 16949 where automotive applies. The exact scope depends on the final product and the market, so confirm it with the importer and the assembly standard.
Materials and finishes
Finishes include tin, nickel, passivation and powder coating. The finish is part of the function: it can change contact resistance, corrosion life, solderability or the ability to dissipate heat.
State the finish standard, thickness and any bare or masked zones. If the part is plated after forming, check that the coating survives the bend or crimp.
Supplier and programme fit
A programme for EV and battery packs needs more than a part price. It needs a supplier that can hold the drawing revision, control change, keep traceability and release the inspection pack with the shipment.
We can support prototype, pilot and production stages, with first article, PPAP or a delta FAI where the programme requires it. Tool ownership and change control should be agreed before the first order.
What to send
Send the drawing, the application, the annual volume, the release size, the material, the finish, the test requirement and the destination. Add the assembly drawing and the applicable standard if they exist.
A short application note is often more useful than a longer drawing pack. It tells the supplier which features are functional and which are only geometric.
| Requirement | What to send | Why it matters |
|---|---|---|
| Application | cell interconnects, fusing, isolation, vibration and thermal cycling | Sets the real duty, not just the drawing |
| Material | music wire, 302 and 316 stainless, phosphor bronze and beryllium copper | Strength, conductivity, fatigue and finish |
| Test | pull, weld shear, thermal cycling and insulation | Proves the part in the intended duty |
| Standard | IATF 16949 where automotive applies | Defines the evidence and release route |
Questions buyers ask
Can Qumek make wireforms for EV and battery packs?
Yes, where the drawing, material and inspection requirements fit the process. We review the application and the assembly context before quoting.
Which tests should we specify?
Start with pull, weld shear, thermal cycling and insulation. Add any test that the final product standard or the customer requires. The first article should show the test method and the result.
Can you support a prototype and then production?
Yes. The prototype route may use different tooling from production, but the drawing and the critical characteristics should stay the same. A delta FAI or PPAP can bridge the change.
What should the RFQ include?
The drawing, application, volume, material, finish, test requirement, destination and any standard or declaration. The more of that you provide, the fewer assumptions sit in the quote.