Smart development approach leads to success story

Out of a technical challenge comes a success story: Working in close collaboration with an international customer, SFS developed high-precision fastening elements for EV batteries – reliable, precise and efficient. What made this possible was a smart development approach that saves time, cuts costs and allows all parties to speed up their power to innovate: that was how a simple request led to a strong partnership as equals.

Added value

Developed in no time at all thanks to perfectly optimized processes
Our far-reaching expertise allows us to develop solutions tailored exactly to customers’ needs
Close collaboration and efficient procedures save time and money for all parties

A global manufacturer of electronic components asked SFS to develop high-precision, robust and cost-efficient components for a new series of batteries for EVs. The focus was on key parts for high voltage connections that require maximum reliability and safety, as well as the best possible conductivity. These components were made using cold forming and in combination with the plastic injection molding technology – a targeted combination of the two technologies to turn functional, economical solutions into production-ready assembly methods.

Efficient development is key
Right from the beginning of the project, the SFS Group opted for a holistic development approach based on the principle of simultaneous engineering. This involved the customer’s development departments working in close collaboration with our internal teams. As early as the initial phases of product development, staff from construction, material sciences and production worked hand in hand to fulfill the customer’s individual requirements. There are several benefits of simultaneous engineering:

INDUSTRIAL_AUTOMOTIV_3566 — Contact ring – custom-designed and -manufactured

Parallel processing in the various teams and phases significantly shortens the development time. In this case, it meant that the product was able to come onto the market sooner, thereby strengthening the competitive advantage.
As a result of the close collaboration and regular communication, costly iteration loops were avoided and development costs were reduced significantly.
We have systematically improved the project and production processes. Manufacturing aspects were taken into account as early as the construction phase, making series production more efficient. Because all those involved fully understood the application and function of the parts, we were able to avoid additional processes during production.

E_Mobility_3 — Battery of an electric vehicle

Trust creates innovative solutions
The collaboration between SFS’s development departments and the customer was characterized by mutual trust and open communication. Regular workshops and the cooperation between interdisciplinary project teams enabled challenges to be identified at an early stage and mastered jointly. The customer in particular highlighted SFS’s ability to respond flexibly to the changes requested and implement them quickly and efficiently.

industrial_metal_plastic_combination_6_1920px — Plastic-coated screw – smart combination of two technologies

The result: high-precision, robust components
High-precision, ready-to-use parts with outstanding mechanical qualities were made using state-of-the-art cold forming and plastic injection molding procedures. In developing these customer-specific products, not only did SFS meet the high demands placed on it with regard to precision and reliability, it also created added value in terms of resilience with specially finished copper parts and individual surface treatment.

These fastening elements play a key role in the end customer’s new EVs and are pivotal to the efficiency and safety of the vehicles.

A partnership that makes a difference
The transformation from a supplier to a strategic development partner has not just made SFS more competitive, it has also strengthened the bond between us and our customers and cemented the partnership. This success story impressively shows how a vision becomes reality and lasting added value is created through strategic collaboration.