In December 2025, with the rapid evolution of the EV industry, the highly anticipated GB 38031-2025 new national standard for power battery safety has been officially implemented. Compared to the 2020 version, the new standard imposes nearly stringent requirements on thermal runaway propagation time, mechanical shock resistance, and flame retardancy of components. For battery PACK manufacturers, this is not just a safety challenge but a game of R&D speed and cost control.
In this context, traditional mold-based production modes, with their long cycles and high modification costs, struggle to adapt to the frequent testing and design iterations required under the new standard. The "mold-free" manufacturing solution proposed by Hongchuan Precision (HC-SP) is becoming the key to breaking through the industry bottleneck.
1. Rapid Response to New Standards: Flexibility of Precision Stamping
GB 38031-2025 requires battery packs to maintain structural integrity under more extreme vibration and shock. This means the design of internal connectors may need to undergo dozens of fine-tuning validations. By adopting HC-SP's Precision Stamping technology, utilizing a combination of NC punching and laser cutting processes, samples can be delivered rapidly without expensive mold investments. Whether it's complex bending structures or special heat dissipation hole designs, we can complete the prototyping of customized stamping parts within 24-48 hours, helping customers seize market opportunities.
2. Tackling Thermal Runaway: Heat Dissipation and Current Carrying of Busbars
The new standard sets specific indicators for temperature rise control under high-rate charging and discharging. Traditional wire harness connections can no longer meet the demands of high-voltage architectures. The SMD Busbar developed by HC-SP uses high-purity copper combined with unique surface treatment processes, which significantly reduces contact resistance and optimizes heat dissipation channels. As a high-performance current-carrying copper bar, it effectively mitigates heat accumulation effects, ensuring the electrical safety of battery modules under extreme conditions.
3. Vibration Resistant Connection Solutions: Evolution of Terminals and Nuts
In mechanical strength tests, the loosening of connection points is one of the main causes of failure. To meet the new standard's requirements for vibration resistance, our Welding Terminals have undergone structural optimization to enhance their grip on the PCB. Simultaneously, using high-precision SMT Nuts allows for fully automated SMT reflow soldering. This SMT Nut not only improves production efficiency but its welding strength also far exceeds traditional clinching processes, perfectly aligning with the strict definition of connection reliability in GB 38031-2025.
4. Balancing Cost and Efficiency: From Selection to Mass Production
Facing raw material price fluctuations and rising compliance costs, how can BOM costs be precisely controlled? You can use the Price Calculator on our website for a preliminary budget, or visit the Product Center to view standardized components. For complex non-standard requirements, our Selection Guide provides detailed model coding rules to help engineers quickly lock in the optimal solution.
Hongchuan Precision has been deeply cultivating the industry for years, committed to driving battery technology progress through process innovation. If you have any questions about component design under the new national standard, welcome to read About Us to learn more about our manufacturing processes, or directly Contact Us for free samples and technical support.