Aluminum 6061 Lifting Sleeve

1. Product Overview

The Aluminum 6061 Lifting Sleeve is a high-precision structural component specially developed for EV battery packs. As a critical load-bearing part, it is responsible for lifting, positioning, and securing battery packs during assembly and transit, ensuring reliable safety and structural stability in high-volume production. Featuring a flanged hollow sleeve structure with precision top threads and high-precision mating surfaces, the product meets stringent dimensional tolerance and safety load standards, making it ideal for standardized, large-scale manufacturing of electric vehicle battery systems.

2. Advanced Manufacturing Process

Replacing the conventional full CNC milling process, our Aluminum 6061 Lifting Sleeve adopts an optimized composite manufacturing solution: Cold Heading + Minimal Secondary Machining. This process innovation perfectly balances precision, structural integrity, and cost efficiency, providing a mature and reliable solution for low-cost, high-strength precision fastener mass production.

2.1 Cold Heading Blanking: High-pressure cold heading technology forms the integral product blank in a single operation. The process delivers fast cycle times and superior consistency with a material utilization rate of up to 98%. It greatly eliminates the material waste common in traditional bar stock removal processing and achieves nearly zero material loss.

2.2 Minimal Precision Machining: Only critical functional areas, including the top precision threads and seating mating surfaces, undergo limited CNC finishing. This ensures accurate assembly, flatness consistency, and precise thread engagement, fully complying with high-precision assembly requirements for EV battery packs.

3. Core Performance & Verified Advantages

3.1 Enhanced Structural Strength & Improved Safety

Traditional full CNC machining severs the internal grain flow of aluminum material, creating structural weak points that are susceptible to stress fractures under continuous lifting loads and cyclic fatigue. In contrast, cold heading forms metal through high-pressure plastic deformation, preserving continuous, unbroken grain flow along the product’s flange and cylindrical structure. Validated by professional tensile testing, our cold-headed Aluminum 6061 Lifting Sleeve delivers superior stress fracture resistance compared to fully CNC-machined equivalents, substantially improving the safety margin for battery pack lifting operations.

3.2 Higher Production Efficiency & Stable Delivery Capacity

The conventional full CNC process takes approximately 20 minutes to machine a single unit. With our upgraded composite process, cold heading rough forming is completed within seconds, and the total cycle time — including minimal finishing machining — is controlled within 4 minutes per piece. Without additional equipment or floor space investment, the daily output of a single production line increases from 60 units to 300 units, reaching 5 times the original production capacity and fully supporting high-volume mass production and stable delivery requirements.

3.3 Significant Cost Reduction

Leveraging ultra-high material utilization and optimized cycle time, the unit product cost has been reduced from RMB 50 to RMB 20, representing a 60% cost reduction per piece. This effectively lowers customers’ overall BOM costs for battery pack assemblies and aligns perfectly with cost-control targets for large-scale industrial manufacturing.

4. Core Product Value

Through process innovation, the Aluminum 6061 Lifting Sleeve achieves three key upgrades: enhanced structural strength, significantly higher production efficiency, and greatly reduced manufacturing costs. It resolves the inherent drawbacks of traditional CNC processing — high cost, low efficiency, and inconsistent structural performance — while fully complying with the new energy industry’s strict dimensional and safety specifications. It serves as an optimal upgraded solution for EV battery pack lifting components.

5. Application Scenarios

It is widely applicable to various new energy vehicle power battery packs, primarily used for battery pack mass assembly, lifting and transportation, and structural fastening. The product fully meets the lifting and assembly fastening demands of diverse power battery pack designs.