As electric vehicles (EVs) surge in popularity, reliable charging solutions have never been more important. At Davantech, we manufacture high-performance, custom EV charging connectors using precision techniques like CNC metal machining, injection molding, and overmolding.
In this guide, we’ll break down:
✔ How custom EV charging connectors are made
✔ Why precision matters for safety & efficiency
✔ The benefits of custom vs. off-the-shelf connectors
✔ Our advanced manufacturing process
Let’s explore what goes into making these critical components.
How Are Custom EV Charging Connectors Made?
1. Precision Metal Contact Machining (CNC)
The foundation of every reliable EV connector is its metal contacts, which must conduct electricity efficiently while resisting wear.
- Materials Used: High-conductivity copper or brass alloys
- Process: CNC machining ensures ultra-tight tolerances (as low as 0.01mm) for perfect electrical contact
- Why It Matters: Poorly machined contacts lead to overheating, slow charging, or even failure
At Davantech, our CNC machines produce consistent, high-precision metal parts that meet strict industry standards.
2. High-Strength Plastic Injection Molding
Next, the metal contacts are encased in a durable plastic housing.
- Materials Used: Heat-resistant thermoplastics like polycarbonate or nylon
- Process: Molten plastic is injected into precision molds under controlled pressure and temperature
- Why It Matters: The housing must resist heat, UV exposure, and mechanical stress
Our automated injection molding systems ensure every connector is identical in strength and dimensions.
3. Protective Overmolding for Durability
The final step adds an extra layer of protection and style by overmolding a TPE or TPU layer around the assembly.
- Process: A second plastic layer is molded over the assembled connector
- Benefits:
- Enhanced durability against drops, moisture, and wear
- Custom colors & textures to match brand aesthetics
- Better grip for easier plugging/unplugging
Why Choose Custom-Made EV Charging Connectors?
✔ Better Performance & Safety
- Precision-fit contacts prevent overheating and voltage drops
- High-quality materials withstand thousands of charging cycles
- Tested for extreme conditions (heat, cold, moisture)
✔ Perfect Compatibility
- Tailored to your EV’s power requirements (Level 1, 2, or DC fast charging)
- No mismatched connections (unlike generic connectors)
✔ Enhanced Aesthetics: Your own Design
- Custom colors, logos, and finishes for branding
- Sleek, professional look for public charging stations
✔ Longer Lifespan
- Reinforced designs resist wear and tear
- Fewer replacements mean lower long-term costs
Industries We Serve
Our custom connectors are used in:
🔌 Home & Commercial Chargers – Reliable daily charging
🚗 EV Manufacturers – OEM-compatible connectors
🏢 Public Charging Networks – Durable, vandal-resistant designs
⚡ Fast-Charging Stations – High-current capable connectors
Why Trust Davantech for Your EV Connectors?
✅ Advanced CNC & Injection Molding Tech – Precision manufacturing
✅ Strict Quality Control – Every connector tested for performance
✅ Custom Solutions – Designed for your exact needs
✅ Fast Turnaround – Prototyping & bulk production
Get a Custom EV Charging Connector Today
At Davantech, we don’t just make connectors—we engineer high-performance charging solutions built to last.
📩 Need a custom design? Contact us today for a quote!
