Client Industry: New Energy - Energy Storage Systems (ESS)
The Challenge:
A global Energy Storage System manufacturer was scaling production and needed a reliable, high-volume source for millions of mission-critical custom components monthly:
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A unique shoulder bolt for busbar connections, requiring Grade 10.9 strength, superior corrosion resistance, and tight concentricity.
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Vibration-resistant compression springs for battery cell stacking, demanding consistent load performance across wide temperature ranges.
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IATF 16949-level quality control and absolute consistency to ensure system safety and longevity at scale.
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Our Solution:
Tingfeng Hardware deployed a dedicated production cell after a rigorous audit of our cold heading and spring capabilities.
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For the Custom Bolt: We designed a multi-station cold heading die to form the complex shoulder shape efficiently, followed by precision thread rolling. Automated optical inspection verified every piece post-plating.
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For the Springs: Computerized spring coils were tuned for exact force curves. Rigorous stress relieving and presetting ensured long-term stability. Batch sampling for load and salt spray testing was routine.
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For Quality at Scale: Dedicated high-speed machines and real-time SPC (Statistical Process Control) ensured process stability across millions of parts.
Results & Impact:
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Scalable Supply Achieved: Successfully ramped up to supply over 3 million pieces monthly, becoming a primary vendor.
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Zero Field Failures: After 18 months and thousands of deployed units, zero failures have been linked to our components.
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Significant Cost Saving: The cold heading process proved 30% more cost-effective than the client's previous machined alternative.
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Partnership Extended: Now collaborating on value engineering for next-generation products.
Client Testimonial:
“Reliability is non-negotiable. Tingfeng built a quality system around our needs. Their ability to deliver custom parts at this scale with flawless consistency has been instrumental in our production ramp-up.”