Cleanroom products in electric vehicle (EV) production and manufacturing ensure that sensitive components and processes remain free of contaminants.
This article breaks down the key EV manufacturing processes in which cleanroom solutions are necessary and what cleanroom-ready parts are available for engineers and machine builders.
1. Battery Production
Contamination of the battery can be extremely dangerous! It is recommended that battery assembly occur in an ISO Class 7 or 8 cleanroom environment.
EV battery production, particularly for lithium-ion cells, requires an ultra-clean environment to prevent contamination from dust, moisture, or particles, which can decrease efficiency and increase safety risks, such as short circuits or thermal runaway.
However, batteries can be assembled by hand or by machine, but even though machines can create particles, they don’t do so as much as assembling by hand.
Since battery production accounts for about 20% of the total battery cost, finding the right components for designing proper machinery is worth the investment.
Some of the components used during this phase.
Cleanroom Fasteners
Fasteners such as dowel pins, spring pins, and retaining rings ensure secure assembly in battery packs without introducing particulates.
Shims (Plates, Rings, Rectangular)
Precision spacing components like shims maintain structural alignment in battery modules.
Metal Spacers
Metal spacers provide gap control in battery pack designs, helping avoid unintended contact or short circuits.
2. Semiconductor Manufacturing
Semiconductors play a major role in electric vehicle manufacturing, as they offer power management, energy efficiency, and thermal management. They also play a role in communication technology, such as vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I).
Semiconductors used in EVs for motor control, charging systems, and ADAS are highly sensitive to particulate contamination, which can cause chip defects and malfunctioning electronics.
Some critical components include:
Hinge Bases, Plates, and Bolts
These types of components ensure precise assembly in semiconductor fabrication equipment.
Cleanroom Conveyor Rollers
Cleanroom conveyor rollers facilitate the movement of silicon wafers in contamination-free conditions.
Flat Belt Pulleys and Idlers
Flat belt pulleys and idlers optimize material transport within cleanrooms, minimizing particulate generation.
Retaining Rings
Retaining rings provide reliable fastening for sensitive semiconductor components.
3. Precision Assembly
EV motors, drivetrains, and sensors (e.g., LiDAR, radar) assembly requires precision in contamination-free environments to maintain sensor calibration and lubrication integrity.
Microscopic particles can disrupt sensor calibration, leading to inaccurate LiDAR or radar readings, while contaminants in lubricants can cause wear, overheating, and reduced efficiency in motors and transmissions.
Cleanroom conditions prevent corrosion, static discharge, and misalignment, preserving lubrication integrity and ensuring smooth operation. This level of precision enhances long-term durability, safety, and overall EV performance.
Here are some of the components used during assembly:
Leveling Mounts
Leveling mounts help to stabilize assembly machinery to prevent contamination during fine motor and drivetrain assembly.
Fulcrum Pins and Connecting Links
Fulcrum pins and connecting links enable precise motion in assembly systems for EV sensors and mechanical parts.
Metal Spacers and Shims
Metal spacers and shims help to maintain alignment and prevent wear.
Hinge Pins
Hinge pins are used in modular cleanroom enclosures for accessing precision assembly tools.
4. Research & Development (R&D)
Prototyping and testing EV batteries and electronics in R&D require contamination-free environments to guarantee reliable performance data.
Clean environments prevent unwanted variables that could compromise data integrity, ensuring that performance, safety, and longevity assessments are precise.
This level of control allows you to make informed design improvements, optimize efficiency, and meet strict industry standards before mass production.
Here are some essential components used during the R&D phase:
Configurable Shims and Metal Spacers
Shims and metal spacers aid in designing test rigs and fixtures for battery cells.
Retaining Rings and Cotter Pins
Retaining rings and cotter pins are essential parts that are used for experimental setups of EV motors or electronic systems.
Leveling Mounts
Leveling mounts are used to stabilize R&D equipment, ensuring precise measurements in cleanrooms.
MISUMI Offers Solutions for EV Engineers
MISUMI supports electric vehicle manufacturers and engineers with a comprehensive catalog of products and engineering tools.
We offer all the parts you need to fulfill your BOM, including cleanroom-ready parts that are cleaned, packed, and delivered straight to your facility. Known as clean and pack, this solution has helped our customers save time and money.
MISUMI’s clean and pack option is available for hundreds of mechanical parts.
