As the automotive industry pivots toward a cleaner, smarter, and more connected future, electric vehicles (EVs) are rapidly replacing traditional internal combustion engine (ICE) vehicles. But with this technological evolution comes a set of new engineering challenges—particularly when it comes to the components that hold it all together: fasteners.
Fasteners in electric vehicles are not merely metal pieces joining parts. They must withstand high electrical loads, resist corrosion, minimize weight, manage heat, and often comply with unique assembly constraints. At Ridhi Fasteners, we have adapted our expertise in cold forging and automotive engineering to meet the specific fastening demands of the EV era.
In this blog, we’ll explore how fasteners for EVs differ from those in conventional vehicles, the importance of customization, and how Ridhi Fasteners delivers solutions that support the automotive industry’s shift to electric mobility.
Why Fasteners in EVs Are Different
Electric vehicles bring an entirely new set of mechanical, thermal, and environmental considerations. Here’s why EV fasteners need a different approach:
1. Battery Integration
EVs rely on high-voltage lithium-ion battery packs. Fasteners in and around the battery system must:
- Prevent thermal runaway
- Avoid electrical conductivity between sensitive components
- Be lightweight yet strong
- Provide sealing to prevent moisture ingress
2. Thermal Management Systems
EVs require advanced cooling systems for batteries, inverters, and motors. Fasteners in these areas must:
- Withstand thermal cycling
- Resist coolant corrosion
- Seal tightly under pressure and vibration
3. Lightweight Design
To extend driving range, manufacturers are adopting lightweight materials like aluminum, magnesium, and carbon fiber. Fasteners must be:
- Weight-optimized
- Compatible with soft materials
- Resistant to galvanic corrosion
4. Compact and High-Precision Assembly
Tightly packed electrical architectures demand fasteners that:
- Are small and space-efficient
- Enable quick, automated assembly
- Maintain tight dimensional tolerances
The Role of Custom Fasteners in EV Manufacturing
Standard fasteners often fall short in EV applications. That’s where customization becomes essential.
At Ridhi Fasteners, we develop bespoke fastener solutions tailored to the unique technical and design requirements of EV manufacturers.
Our Custom Fastener Capabilities Include:
- Application-specific geometries (e.g., asymmetrical heads, low-profile designs)
- High-performance coatings (for insulation, corrosion resistance)
- Unique thread profiles for vibration and thermal expansion resistance
- Insulated washers and sleeves for battery assemblies
- Non-conductive fasteners for safety-critical zones
- Color-coded or laser-marked parts for robotic assembly lines
Key Fastener Applications in Electric Vehicles
1. Battery Packs
Battery enclosures are the largest and heaviest components in EVs. They require:
- Sealing fasteners to protect from dust and water ingress (IP67/IP69K standards)
- Insulated studs and nuts to prevent electrical shorts
- Bolts with torque-limiting features to prevent over-compression of battery cells
Ridhi Solution:
Cold-forged high-strength bolts with nylon patches and EPDM washers, paired with low-conductivity coatings like Geomet or epoxy, engineered for battery systems.
2. Electric Motors and Drives
EV motors generate vibrations and heat similar to internal combustion engines. Mounting them demands:
- High-fatigue-resistance fasteners
- Anti-loosening features like serrated flanges or thread lockers
- Corrosion protection for aluminum motor housings
Ridhi Solution:
Custom flange bolts and vibration-resistant studs with rolled threads, black oxide finish, and optional thread-locking patches.
3. Power Electronics (Inverters, DC-DC Converters)
These components require high levels of electrical isolation and are often cooled using liquid-cooled plates.
Ridhi Solution:
Fasteners with non-conductive coatings, thermal barrier sleeves, and dual-seal flanges for heat sink assemblies.
4. Charging System Mounts
The charging port and its support frame require weatherproof fastening solutions with impact resistance.
Ridhi Solution:
Stainless steel tamper-proof security screws with hex or Torx heads, plastic washers, and custom-colored heads for visibility.
5. Interior and Structural Lightweight Assemblies
Interior modules (e.g., infotainment, BMS enclosures) and external frame parts need:
- Small form factor fasteners
- Plastic compatibility
- Snap-fit alternatives for quick assembly
Ridhi Solution:
Micro fasteners, lightweight aluminum bolts, and thread-forming screws for thermoplastics—ideal for interior panels and electronic modules.
Cold Forging: Perfect for EV Fastener Production
Cold forging is the cornerstone of Ridhi’s fastener manufacturing process. It allows us to create:
- Stronger fasteners (with aligned grain flow)
- Complex geometries without machining
- Tighter tolerances
- Lower weight designs with material optimization
This makes cold forging ideal for EV production, where strength, precision, and weight all matter.
Coatings and Surface Treatments for EV Use
EVs operate in environments that demand advanced protective finishes. Ridhi Fasteners offers:
- Geomet/Dacromet Coatings for anti-corrosion and heat resistance
- Epoxy or Ceramic Coatings for insulation
- Passivation for stainless fasteners
- PTFE-based Dry Film Lubricants for consistent torque
Each coating is selected based on the fastener’s location, material interface, and desired lifespan.
Custom Kitting and Assembly Support
EV manufacturing lines are built for efficiency. We offer:
- Pre-sorted fastener kits for individual components (battery, motor, electronics)
- Barcode or QR-coded labels for traceability
- Pre-applied sealants or lubricants
- Laser-etched part numbers for robot-readable assembly
These features help OEMs save time, reduce human error, and enhance traceability on production lines.
Sustainability: A Shared Value
EVs represent a greener future—and Ridhi Fasteners is aligned with that vision. We support OEM sustainability goals by:
- Using recyclable raw materials
- Reducing scrap through near-net-shape forging
- Operating energy-efficient production lines
- Offering RoHS and REACH compliant coatings
Our processes help manufacturers reduce carbon footprints, optimize supply chains, and deliver more environmentally responsible vehicles.
Trusted by EV OEMs Worldwide
From prototypes to mass production, Ridhi Fasteners supplies custom fasteners for electric vehicles across:
- Passenger EVs (sedans, SUVs, hatchbacks)
- Commercial electric vans and trucks
- Two- and three-wheeler electric mobility
- EV charging infrastructure
We’re proud to be part of the global EV transition with a reputation for precision, reliability, and innovation.
Final Thoughts
Electric vehicles demand more than just different propulsion—they require next-generation fasteners designed for safety, efficiency, and performance under new engineering conditions.
At Ridhi Fasteners, we’ve embraced this shift with passion and expertise. Our custom-engineered, cold-forged fasteners are built for the demands of the EV age—lighter, smarter, and stronger.
If you’re designing or assembling electric vehicles, partner with Ridhi Fasteners to power your platform—bolt by bolt, innovation by innovation.
