Electric Vehicles (EVs) - IATF 16949:2016 Certified

Electric Vehicles (EVs) are ground, airborne or seaborne vehicles containing one or more electric motors. While there are a number of different types, the automotive EV makes up the majority and the market continues to grow and evolve as new technologies and innovations are introduced providing better range and shorter charging times.

Electric vehicle x-ray

Electrical Vehicles Innovation

New EV cutting-edge technologies often require metal components with very tight specifications and tolerances. Weiss-Aug Group has over 30 years of experience in the Automotive industry and has the expertise and capabilities to meet these demanding requirements from the prototyping stage to full-scale manufacturing.

With extensive capabilities to prototype and provide early engineering support, we specialize in partnering with our customers for high power, hybrid, and electrification projects.

High-power busbars

Design and Development Support

Our new product development engineers have a wealth of experience in automotive prototyping and understand your requirements for developing a robust, cost-effective, repeatable, and reliable part.

In addition to the general requirements of product design and prototyping, we can assist you with your specific automotive prototyping requirements.

  • We understand your need to meet milestones for a model-year project, as well as the ability to move quickly from prototype to production.
  • Our quality team is involved in the prototyping stage to ensure that critical dimensions and requirements are considered early on for faster PPAP later in production.

Contact us to learn how you can benefit from a service designed with process efficiency through reduced steps, reduced cost, an accelerated time to market, and improved product performance. We look forward to introducing you to our award-winning team of skilled toolmakers, process and manufacturing engineers.

"Our goal is to help our customers develop concepts into a robust manufacturing program to meet and exceed demanding automotive requirements." - Virgil DeLay, VP, Diemasters Division

Automotive Assemblies

Weiss-Aug Group supplies the custom, highly engineered automotive assemblies, producing them according to your needs:

Semi and Fully Automated Work Cells

  • Fully automated cells for high volume complex automotive programs
  • Robotically assisted inspection, electrical testing, and specialized packaging
  • In-house automation group focuses on zero defects, reducing labor cost, and improved efficiency
  • Integration of Machine Learning utilizing advanced Artificial Intelligence developed in house by our Lupine Research division

Assembly Services Including:

  • Heat staking
  • Crimping and joining
  • Welding
  • PEM insertion, orbital and radial riveting or ring staking

Manual Assembly

Our Mexico facility offers full capabilities from stamping to injection molding and the lowest landed cost of manual assembly.

Robot lowering assembled component into tray
Assembly_Diemasters_2022 (22)
Mexico Facility Assembly

Automotive Metal Stamping Components

Small and Miniature Metal Stamping Components

Weiss-Aug started as a stamping company over 50 years ago. Our focus on complex, high precision, and miniature high-speed stamping shines through in our automotive projects. Utilizing high-speed Bruderer presses that range from 20 to 90 tons, capable of speeds up to 1600 strokes per minute, and an in-line 100% vision system for monitoring critical features combined with fully automated assembly, we can guarantee completely defect-free products that meet and exceed quality standards. From stainless steel to copper and gold plated materials, we can supply stampings loose or reeled for your application.

Medium-Size Automotive Metal Stamping Components and Assemblies

For larger stampings, such as automotive electric vehicle busbar applications, we offer stamping capabilities from 60 to 350 tons with our thicker materials being stamped by our Diemasters division. We stamp copper, steel, and other materials (up to 6mm or .25 inches) exclusively on best-in-class Minster stamping presses. If your automotive metal part requires assembly, our robotic welding cells with automated leak testing and other secondary operations can provide you with a full assembly for your needs.

With a fleet of 50+ presses in the US and Mexico, we provide millions of quality metal stampings to North American automotive companies every day.

Automotive stamping

Automotive Insert Molding and Overmolding

Specializing in high-volume applications, our automotive injection molding, and automotive insert molding is perfect for the high quality and precision needs of this industry. We work with a variety of resins and utilize both horizontal and vertical machines, as well as reel-to-reel and micro-molding. Force testing, electrical testing, and hard gauges allow us to evaluate the functionality of all products. We can offer you automotive molding services in our US locations or from our Monterrey plant in Mexico.

Key Product Groups

Electrification Components

  • Busbars
  • Charging Station Components
  • Connectors
  • Modules
  • Sensors
  • Inverters
  • Battery Cable Connectors
  • ECU Housing

Packging Solutions

  • Sensor Housings
  • Switch Components
  • Ignition Components
  • Fuel Delivery Components
  • Board Level and Surface Mounts

Lead-Frames and Terminals

  • Terminals
  • Contacts
  • Switches
  • Solderable Contact Leads
  • Voltage Regulators
  • Compliant Pins
  • Bettery Contacts

Mechanical Components

  • Detent Levers (DLA)
  • Structural Frames
  • Lighting Components
  • Safety Components
  • Actuators
  • Compliant PinsPetal Components
  • Machines Inlets

Challenge: Produce a reel-to-reel gold plated component with multiple part number configurations

Solution: Build an inline 8 Cavity mold with an integrated cut-off post-press and automated tube loading for packaging.

Outcome: A very cost-effective process for the customer that allows them to seamlessly load the switch into the next step in their manufacturing line.

Industries Served

How can we help?

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“Today through use of innovative lean manufacturing techniques, expansive engineered processes and a strict adherence to the highest quality and safety standards, our stamping plant has successfully produced recent multi-year PPM ratings of less than one. Our stamping philosophies have also earned us high supplier ratings with both automotive and medical customers and continuous positive auditing scores from yearly ISO 9001:2015, ISO 13485:2016, ISO 14001:2015 audits and IATF 16949:2016.”

— Dieter Weissenrieder, CEO and Founder