Powering the Shift: Precision Engineering for Electric Vehicle Manufacturing

As the global transition to electric vehicles (EVs) gains momentum, automotive and transportation manufacturers face a new era of engineering complexity. Electrification demands more than just replacing combustion engines with electric drivetrains—it requires a reimagining of vehicle architecture, component design, thermal performance, and advanced materials.

To meet these challenges, OEMs and Tier 1 suppliers are turning to trusted precision engineering partners who can support accelerated development cycles, ensure functional performance, and uphold the highest quality standards. At Protec Group, we are proud to be part of this transformation, delivering critical EV components and engineering solutions for the future of electrified transport.

Precision Engineering for the EV Industry

Electric vehicle platforms require unique mechanical and electrical systems, each with specific geometric, thermal, and structural demands. Protec’s engineering capabilities are built to deliver precision, reliability, and performance in:

• Battery enclosures and structural housings – engineered to ensure thermal management, crash resilience, and seamless vehicle integration.
• Busbars – precision-machined aluminium and copper conductors designed for efficient high-voltage power transfer.
• Cooling systems – including machined cooling plates and heat exchangers to regulate battery and inverter temperatures.
• Motor housings and drivetrain casings – tight-tolerance machined parts supporting high-speed rotation and electromagnetic shielding.

By collaborating with our clients from the earliest stages of design, we ensure that every part delivers exceptional performance, durability, and integration within the wider EV architecture.

Accelerating EV Innovation from Prototype to Production

With aggressive development timelines across the EV market, Protec enables fast, flexible, and cost-effective transitions from concept to production. We offer:

• Rapid prototyping with CNC and additive technologies
• DfM (Design for Manufacture) support using advanced CAD/CAM
• Scalable short-run manufacturing for pilot builds and low-volume platforms
• Streamlined quality assurance with traceability and digital validation

We specialise in high-precision, low-to-medium-volume manufacturing, ideal for the bespoke and rapidly evolving nature of electric vehicle development.

How Our Capabilities Drive EV Manufacturing

Additive Manufacturing
Additive manufacturing enables rapid development of EV-specific components such as lightweight brackets, sensor housings, and enclosures for electronics. It supports part consolidation, weight reduction, and faster iteration during concept and prototyping stages.

Moulding and Forming
We provide formed and moulded solutions for interior EV parts, protective covers, and panel components. These processes are ideal for producing thermally and structurally robust elements used in cabin components, shielding, and underbody systems.

Precision CNC Machining
Our CNC machining capabilities produce high-tolerance aluminium and composite components for battery trays, cooling plates, e-motor housings, and drivetrain components. This ensures critical alignment, sealing, and mechanical performance in EV assemblies.

NVH Solutions
Electric vehicles reduce engine noise but reveal other sources of vibration and acoustic disturbance. Protec supports OEMs with NVH solutions such as isolation mounts, acoustic damping structures, and precision-fit assemblies to enhance passenger experience and component lifespan.

3D Scanning and Metrology
We use 3D scanning for reverse engineering and design validation of complex parts in EV systems. With metrology-grade inspection, we ensure geometric accuracy for high-voltage components, thermal interfaces, and battery system assemblies.

Extrusions
Protec machines and assembles custom aluminium extrusions used in battery frames, mounting rails, and cooling structures. These lightweight, modular solutions are essential for vehicle efficiency and platform scalability.

Composites
We fabricate carbon fibre and glass-reinforced polymer components for EV structures and housings. These materials offer strength, reduced mass, and thermal insulation—key benefits in improving EV range and safety.

Fabrication and Assembly
From multi-part battery housings to kitted assemblies, we combine in-house fabrication with mechanical assembly to deliver complete modules ready for line-side integration. Our team ensures every unit meets strict automotive standards and design intent.

Find out more about our capabilities below:

Automotive-Grade Quality: IATF 16949 & ISO 9001 Certified

Quality is fundamental in automotive engineering. Protec’s IATF 16949 and ISO 9001 certifications validate our commitment to meeting global automotive standards. Our processes include:

• Material traceability and process documentation
• Precision inspection with calibrated CMM and digital tools
• First-article, in-process, and final quality control
• Continuous improvement through internal audit and corrective action

We understand that in electric vehicle systems, even the smallest tolerance deviation can affect safety, performance, or efficiency.

Strategic Partnerships for Electric Mobility

Protec collaborates with clients across:

• Passenger EV and commercial electrification projects
• EV battery and powertrain innovation
• High-performance and motorsport EV applications
• Off-highway and industrial electric vehicle platforms

Operating from our Warwick-based facility, we support UK and global manufacturers with agile engineering support, precision component delivery, and dependable quality.

Precision Engineering for a Sustainable Future

Electric mobility is reshaping the transport landscape—and Protec Group is ready to help you lead. Our expertise in engineering for EV platforms enables innovation, reduces development cycles, and ensures precision at every stage of the product lifecycle.

Looking for an engineering partner in EV development? Contact Protec today.