Custom Cleanliness-Compliant Protection for E-Motor and
E-Axle Sealing Areas
Customize Design
Cleanliness Assurance
Process Reliability
Advanced Oil Sealing Protection with Cleanliness and ESD Options
In high-precision e-mobility applications, even the smallest contamination can compromise performance and reliability.
This case study shows how a tailored, cleanliness-compliant protection solution was developed to safeguard critical sealing areas of e-Motors and e-Axle systems, ensuring secure handling, clean assembly, and full process integrity from production to final installation.
About Our Partner
A global automotive technology manufacturer operating in a highly regulated environment where component protection, cleanliness, and traceability are essential throughout production and assembly.
Challenges
Contamination & Cleanliness
During the production of e-Motors and e-Axle drive systems, sensitive interfaces required reliable protection against oil, dust, and process contamination. In addition, all components had to comply with strict Cleanliness standards, with ESD protection required for selected applications.
Fit & Sealing Accuracy
Standard off-the-shelf parts did not fully match the counterpart dimensions, which made it difficult to achieve precise sealing and secure positioning. The customer therefore needed customized protection that would fit exactly and remain stable during handling.
Handling & Assembly Safety
The solution also had to stay securely in place during internal logistics and transport, while still allowing for easy and safe removal on the assembly line, without causing damage, contamination, or delays in the assembly process of sensitive interfaces.
Our Solutions
DBI developed a fully customized protection concept, designing new parts specifically adapted to the customer’s counterpart geometry.
The parts were developed in close cooperation with the customer’s engineering team, ensuring perfect dimensional match, sealing performance, and process compatibility.
Precisely fitting Oil Sealing Protection Caps engineered to cover and protect critical interfaces.
Production in Cleanliness conditions, with the option of ESD-safe material where required.
A few alternative design concepts, offering different cost structures.
Optimized geometry for secure fixation combined with easy handling.
Value-Added Services
Beyond part design and manufacturing, DBI provided:
Design optimization based on counterpart dimensions and handling requirements
Consultation on material selection for Cleanliness and optional ESD protection
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