THE SECTOR
Electric Vehicles
The electric vehicle market is continuously evolving, representing one of the most significant transformations in the automotive industry.
This transition is driven by factors such as advancements in battery technology, policies supporting sustainable mobility, and the growing interest in low-environmental-impact solutions.
At the same time, the sector is undergoing a phase of stabilization, with market dynamics influenced by incentives, the expansion of charging infrastructure, and the evolution of global offerings. In this context, manufacturers and institutions are adjusting strategies and investments to ensure balanced growth across the sector.
THE CLIENT
Our client is a global leader in providing cutting-edge mobility technologies for the automotive industry.
With solid experience and deeply rooted values in innovation and manufacturing excellence, the company is committed to shaping the future of mobility. By collaborating with customers and partners, it drives the evolution of the sector with a strong focus on safety, sustainability, and advanced connectivity.
Sealing Solutions for Electric Vehicle Rear Differentials
THE CHALLENGE
The client’s business unit, specialized in electric powertrains, partnered with Athena to develop a sealing system for the rear differentials of a well-known electric vehicle brand.
Due to the specific requirements of the electric vehicle segment, the requested seals had to withstand high temperatures and ensure compatibility with specific fluids to guarantee efficiency and durability under dynamic operating conditions.
Material Selection and Geometry Optimization
THE SOLUTION
For each sealing requirement, Athena provided its own material proposal and manufacturing optimizations, including the molding of specific reliefs, while also recommending further technical investigations to assess critical areas. Specifically, multiple tests were conducted using Fuji paper to measure the surface pressure of the requested seals.
Additionally, Athena carried out Finite Element Analysis (FEA) to simulate real operating conditions of the sealing system, enabling the identification of critical parameters even before prototype testing. This approach helped prevent potential issues such as seal deformation during tightening and allowed for targeted and efficient corrective actions.
The final test results confirmed that the sealing solution met the required performance standards, with practical tests validating the effectiveness of the new design in ensuring the necessary sealing and impermeability. To complete the study, Athena also conducted an IP test at the client’s request.
Applications
Automotive, engines and vehicle parts
Our expertise deployed
Our expertise
