Cabin and body part
- Judged on look, feel, squeak, and fit to the next panel
- PP, ABS, PC/ABS, and TPE cover most of it
- Color is styling
Industry
Injection Molding for Electric Vehicles
An electric vehicle carries plastic parts that sit right next to high voltage conductors. They are orange for a reason, and the resin behind that color is chosen for different things than a cabin trim part.
Two kinds of part
A cabin part and a high voltage part are not the same job
Both are molded plastic on the same car. What they are judged on barely overlaps.
High voltage part
- Judged on insulation, tracking resistance, flame behavior, and heat
- Glass filled PBT, nylon, PPA, and PPS do most of the work
- Orange marks high voltage for anyone servicing the car, and the pigment has to hold that color under heat
Where plastic sits
Molded parts along the high voltage path
From the charge port to the motor, the same few resins keep showing up.
| Part | What it has to handle | Usual resin family |
|---|---|---|
| Charge port housing and inlet | Weather, plug insertion wear, and UV at the body line | Glass filled PBT or nylon, with a TPE seal |
| High voltage connector bodies | Tracking between terminals, latch strength, sealing | Glass filled PBT or PPA |
| Busbar carriers and holders | Heat from current, holding copper in place through vibration | PPS or PPA, often molded around the metal |
| Power electronics covers | Heat next to inverters and chargers, sometimes shielding | Flame rated nylon or PBT |
| Cable clips and routing | Holding heavy orange cables without chafing them | Nylon |
Metal in plastic
Molding the plastic around the copper
Terminals and busbars are often placed in the mold so the plastic forms around them in one shot.
- Insert molding locks the metal in position and removes a press fit or staking step
- Copper and plastic expand at different rates, so the plastic around a busbar is designed to grip without cracking as it heats and cools
- Where the metal exits the plastic is the usual leak path, and it gets attention if the part must seal
- Clearance between exposed conductors is set by the electrical design. The molded part has to hold it without flash or short fills
FAQ
Questions from EV programs
What is tracking resistance and why does it matter?
Tracking is a conductive path that forms across a plastic surface when moisture and dirt meet voltage. Resins are rated for how well they resist it. High voltage connectors and carriers use grades with good ratings, and the geometry keeps the surface path between conductors long.
Why is the orange color specified so tightly?
Orange tells technicians and first responders that a part carries high voltage. The color has to stay recognizable after years of heat, so the pigment and resin are qualified together and color matched to the program standard.
Can a thermoset be replaced with a thermoplastic here?
Often, yes. PPS and PPA handle much of the heat and electrical load that used to call for thermosets. Where a part sits against very high temperatures for long periods, a thermoset may still be the better answer.
What quality documents should the RFQ mention?
List any inspection reports, material certificates, or approval documents your program requires, so they are reviewed with the quote rather than after tooling is ordered.
Keep reading
Related guides
Connectors, battery parts, and the resins that handle heat and voltage.
Connector housings
Latches, terminals, and seals.
Connector housingsBattery systems
Cell holders, frames, and pack lids.
Battery systemsGlass filled PBT
Connector bodies and housings.
Glass filled PBTPPA
Heat and stiffness near power parts.
PPAPPS
Busbar carriers and hot zones.
PPSCable clips
Routing heavy cables without wear.
Cable clipsThermoset molding
When a thermoset still wins.
Thermoset moldingIndustries hub
Every sector page in one index.
Industries hubNext step
Quote the connector with its metal parts
Upload CAD for the plastic and the terminals or busbars it carries, with the resin grade if the electrical design already names one. NetProto manufacturing is ISO 9001 certified.