Detailed Introduction

This cavity insert is tailored to form the compact orange high-voltage connector housing for electric vehicles. The internal precise contour perfectly replicates the terminal slot, mounting lugs and locking buckle structure of the finished plug, ensuring consistent wall thickness for electrical insulation to meet vehicle high-voltage safety standards. The split frame insert structure allows independent disassembly and replacement, reducing full mold maintenance cost when local cavity is worn.

The ultra-precision manufacturing workflow strictly controls surface finish and dimensional stability: complex curved terminal cavities are processed by 5-axis CNC and micro sinker EDM to guarantee accurate pin positioning tolerance; mold steel undergoes vacuum heat treatment to boost thermal stability, resisting deformation under long-term high-temperature injection of flame-retardant filled plastics; nano-level mirror polishing eliminates tiny burrs to prevent plastic flash which may cause high-voltage leakage risks. Optional PVD hard coating can be applied to extend service life against abrasive glass-filled engineering plastics.

All inserts pass full CMM coordinate measurement and surface roughness inspection before assembly, strictly controlling insulation wall thickness, pin concentricity and locking feature dimensional accuracy. We support customized development based on new energy vehicle high-voltage connector engineering drawings or physical samples, adjusting cavity size, pin layout and surface treatment according to vehicle voltage grade, plastic material and production cycle requirements.

Specification Table