As clean energy systems—such as battery enclosures, EV charging infrastructure, and power conversion units—continue to scale, manufacturers need components that are lightweight, reliable, and cost-effective to produce. That’s where sheet metal design for clean energy manufacturing plays a critical role. Optimizing your design early in the process not only accelerates time to market, it also improves performance and reduces production costs.
Below are five key design strategies that support better manufacturability, scalability, and long-term reliability in clean energy applications.
1. Choose Standard Material Thicknesses
In sheet metal design for clean energy manufacturing, selecting standard gauges ensures material availability and predictable performance.
Why it matters:
- Reduces lead times and costs
- Improves compatibility with forming processes
- Supports weight reduction in EV and energy storage systems
Using standard thicknesses also supports sustainability goals by minimizing waste in high-volume manufacturing.
2. Simplify Bend Geometry
Complex bends increase cycle time and risk of failure—especially in aluminum and specialty alloys used in clean energy systems.
Design best practices:
- Maintain a minimum bend radius of 1x material thickness
- Avoid placing bends near holes and edges
- Consolidate bends to reduce secondary operations
These techniques improve both consistency and structural integrity in sheet metal design for clean energy manufacturing.
3. Standardize Hole Sizes and Features
Standardization is essential when building scalable clean energy equipment.
Recommendations:
- Use common fastener hole sizes across components
- Design with standard tooling in mind
- Leverage laser cutting when tighter feature control is needed
Doing so supports repeatability, especially in enclosure systems and thermal management components.
4. Prioritize Assembly Efficiency
In clean energy manufacturing, design decisions made early on directly impact assembly time, labor cost, and system performance.
Design for assembly by:
- Using self-clinching hardware instead of welds when possible
- Integrating tab-and-slot features for accurate alignment
- Reducing the number of parts through component integration
These strategies ensure that sheet metal design for clean energy manufacturing supports rapid scaling.
5. Plan for Finishing and Electrical Performance
Finishes are not just cosmetic—they impact conductivity, corrosion resistance, and environmental durability.
Key considerations:
- Chemical conversion coating maintains conductivity
- Anodizing protects aluminum in outdoor environments
- Grounding points should be designed into the part early
By factoring finishing processes into your initial design, you avoid costly redesigns during validation and certification stages.
Conclusion
Effective sheet metal design for clean energy manufacturing improves manufacturability, reduces costs, and enhances overall product performance. By integrating these principles at the design stage, OEMs can accelerate innovation while ensuring components meet the demands of next-generation energy systems.
At AMP, our engineering team works directly with clean energy manufacturers to optimize sheet metal parts from concept to full-scale production, ensuring efficiency, repeatability, and reliability in every component.
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