Real projects, real results. Explore how Sunmy has helped OEMs, engineering teams, and product developers across Europe and North America bring their designs to life — from complex CNC machined parts and precision turning to stamped components, castings, and injection-molded assemblies.
Each case study shows the challenge, the process, and the outcome — including how we handled material selection, tolerances, surface finishing, and quality verification with CMM and FAI.
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NEV Motor Housing
High-Pressure Die-Cast Aluminum Motor Housing for New Energy Vehicles
Vacuum-Assisted High-Pressure Die Casting (HPDC), 5-Axis CNC Milling, Helium Leak Testing
The client encountered recurrent micro-porosity in the thick-walled bearing support sections during standard die casting, leading to coolant cross-contamination under 3-bar hydrostatic testing. Furthermore, thermal distortion post-casting caused the main stator bore coaxiality to drift beyond the 0.05mm threshold, resulting in unacceptable NVH (Noise, Vibration, and Harshness) levels at high RPMs.
Sunmy Hardware engineers conducted advanced Moldflow analysis to optimize gating velocity and implemented a high-vacuum HPDC process to eliminate gas entrapment. To address the porosity in thick sections, we integrated localized squeeze pins into the mold design for active densification during the solidification phase. Post-casting, all critical mating surfaces and bearing bores were machined in a single setup utilizing our 5-axis HAAS CNC machining centers to guarantee strict geometric tolerances and alignment.
The optimized process yielded a 100% pass rate in 5-bar helium leak tests and strictly maintained bore coaxiality within ±0.02mm. We successfully achieved an initial production run of 1,000 pieces with a stabilized 15-day delivery cycle for mass production.
Established in 2016, Sunmy specializes in custom metal and plastic parts made from 2D drawings, 3D models, or physical samples. Our capabilities include CNC machining, precision turning, casting, sheet-metal stamping, injection molding, tooling development, surface finishing, and assembly.
