Case Study:
High-Performance EV Challenge
Complex, high-precision component
Internal splining at different depths & dimensions
Very short lead time
Stainless steel with a 0.4 Ra finish
Problem
Complex component, short lead time
Our client required a highly toleranced driveshaft for an advanced, high-performance prototype electric vehicle they are developing. The design required a lightweight shaft, 200mm long, 60mm diameter, splined at both ends, in stainless steel with a 0.4 Ra finish. The splining was internal, at different dimensions and depths. Lead time from the initial design received to client delivery was seven days.
Solution
EDM team use a bespoke solution
The NTG team initially worked to the client’s design to manufacture the blank profile for the parts. Access and accuracy required spark erosion so our EDM team machined the internal splines after producing a bespoke EDM electrode especially for the job. The team used our new Sodi-Tech AD55L EDM machine, shown below. The spark erosion process was programmed to run lights out to save time. Post EDM, the component was finished to 0.4 Ra using our specialist grinding facilities.
Result
The component was completed right first time to the exact design specifications despite the tight timescale and demanding tolerances. Delivery was seven days after the design was first received by the NTG engineering team.


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