Category Archive: Uncategorized

How H&S Manufacturing Supports Ohio’s Defense Manufacturing

A strong defense industrial base (DIB) is crucial to providing the U.S. Department of Defense with the products, materials, and services necessary to maintain national security. Both private and public companies contract with the Department of Defense to create a broad supply network that reduces reliance on a single source or location. A regionally specialized DIB reduces disruptions, shortens supply lines, and minimizes transportation vulnerabilities. These regional suppliers often have specialized knowledge and expertise relevant to their geographic location, supporting innovation for specific defense technologies and capabilities.

H&S Manufacturing is a key regional supplier to Ohio, supporting government and defense contractors with a range of manufacturing services compliant with DoD regulations. Since 1968, our commitment to quality and prompt turnarounds has made us a standout defense industry supplier. Here, we’ll explore the role of regional parts suppliers in defense and how H&S Manufacturing’s capabilities contribute to mission-critical projects in Ohio.

The Critical Role of Regional Parts Suppliers in Defense

Regional defense industrial parts suppliers are the backbone of the defense supply chain and a vital part of the state economy. Proximity to local defense contractors improves collaboration and accelerates response times. When these companies establish ongoing contracts with the DoD, they create a strong local industrial ecosystem and help support the state economy.

As home to the National Air and Space Intelligence Center (NASIC) at Wright-Patterson Air Force Base and the Air Force Research Laboratory, Ohio has a strong defense industry presence. H&S Manufacturing holds a pivotal position in Ohio’s defense ecosystem, with government and military fabricating services directly aligned with the needs of Ohio-based contractors. With sheet metal fabrication capabilities in compliance with Mil-Spec standards and capabilities to handle Covered Defense Information (CDI), H&S is prepared to work closely with contractors to supply defense products and services that meet expectations for quality, performance, and budget.

Precision Components for Defense: H&S Manufacturing’s Capabilities

H&S Manufacturing’s high-quality, Mil-Spec-compliant metal fabrication services are ideal for outfitting the military with durable parts and products that offer consistent performance in challenging environments. Our capabilities include:

• Sheet metal fabrication. With our custom sheet metal fabrication services, precision is key. We perform cutting, bending, grinding, welding, and more to produce prototypes to high-volume orders of virtually identical parts that comply with Mil-Spec standards.
• Precision machining. Our ITAR-compliant facility is equipped with advanced CNC equipment producing tight tolerances (down to ±.001 in). We conduct services that include boring, milling, drilling, tapping, and more, creating custom repeatable parts to exacting specifications.
• Laser cutting. Our advanced metal laser cutting services are compatible with a wide range of materials, making intricate cuts with precision and speed.
• Custom form-in-place (FIP) gaskets & custom box builds (electromechanical assembly). We produce liquid form-in-place custom gaskets in various bead sizes to support complex defense requirements. Our team also assembles custom box builds for various electromechanical projects.
• UAV Sealing. We have the expertise and experience with sealing and gasketing materials for UAV applications in a variety of industries. Our team can assist with material evaluation and selection, and provide a range of sealing and fastening solutions to protect both UAV equipment and its cargo.
• Robotics. Our robotics manufacturing requires advanced precision engineering and fabrication techniques. We leverages every available resource to produce the most accurate and effective industrial automation parts for high-performance applications. Our robotics automation experts wield vast experience in a broad range of custom metal fabrication and CNC machining methods.

Meeting Stringent DoD Requirements

H&S Manufacturing is ISO 9001:2015-certified, AS9100D-registered, AS9146 compliant, and ITAR-compliant, committed to providing the highest quality products with the precision required to meet DoD specifications. We are capable of meeting various Mil-Spec standards and handling Covered Defense Information (CDI) compliant with DFARS Clause 252.204-7012, demonstrating our investment in cybersecurity and physical security.

Strategic Partners in the Defense Supply Chain

As a vital provider in Ohio’s defense supply chain, H&S offers more than just parts. Our experienced team develops long-term relationships with clients to gain an in-depth understanding of their requirements and restrictions. This approach allows us to build strategic partnerships in the defense supply chain to ensure overall quality and satisfaction.

Contact H&S Manufacturing for Your Defense Needs

H&S Manufacturing is proud to serve as a vital part of Ohio’s defense manufacturing supply chain. With custom capabilities and certifications to meet DoD requirements, H&S is prepared to meet your defense machining needs. Contact us today to learn more about our manufacturing capabilities, or request a quote.

Why Dip Brazing Is Critical in Aerospace Manufacturing

The aerospace industry demands advanced processes and materials to produce lighter, stronger, and more reliable components. Every gram of weight matters, every connection must withstand extreme conditions, and every assembly must operate flawlessly in high-stake environments. Achieving these goals requires innovative joining methods along with precision manufacturing.

Dip brazing is one of the few processes that meet these demands for aluminum assemblies. It creates strong, lightweight, and hermetically sealed components that excel in aerospace applications, from avionics to satellites. Learn more about how specialized aluminum dip brazing services meet demanding aerospace requirements.

What Is Dip Brazing?

Dip brazing is a joining process used to bond metal components—most often aluminum—using a filler material with a lower melting point than the base metals. With the filler metal pre-applied, components are immersed in a molten salt bath. The heat melts the filler, which flows into the joints through capillary action and creates a continuous, high-strength bond without melting the base metal.

This method allows multiple joints to be brazed at once, even in complex assemblies with hidden or internal joints. Because the process heats the assembly evenly, it minimizes distortion, making it ideal for precision aerospace manufacturing.

The Benefits of Dip Brazing in Aerospace

• Superior joint strength. The metallurgical bond formed during dip brazing often equals or exceeds the strength of the base metals, offering long-term durability under extreme loads.
• Lightweight assemblies. Dip brazing is perfect for thin-walled aluminum components, reducing weight without compromising strength. This is essential for aerospace systems where every ounce counts.
• Hermetic seals. The process creates leak-tight joints that protect against moisture, contaminants, and pressure loss. In avionics enclosures, heat exchangers, and other sensitive systems, a hermetic seal can mean the difference between mission success and failure.
• Complex geometries. Dip brazing can join intricate designs and multiple parts simultaneously. Internal passages, hidden joints, and fine features are easily handled, making it a preferred method over welding for certain aerospace assemblies.

Aerospace Applications Using Dip Brazing

• Avionics and defense electronics. Sensitive electronics in aerospace systems must be protected from heat, electromagnetic interference (EMI), and environmental exposure. Dip brazing produces lightweight heatsinks, chassis, and housings that provide both structural support and hermetic sealing, extending equipment life and improving reliability.
• Satellite systems. Satellite systems have no margin for failure. Dip brazing enables the fabrication of lightweight structural components, waveguide assemblies, and thermal control devices such as heat pipes and radiators. The combination of low mass, high strength, and hermetic sealing ensures performance under the vacuum and temperature extremes of space.
• Heat exchangers and cold plates. Managing thermal loads is critical in propulsion systems and onboard electronics. Dip brazing allows for the production of leak-proof heat exchangers with intricate internal fins, maximizing surface area for heat transfer. These assemblies maintain consistent operating temperatures, enhancing safety and efficiency.

Why Choose H&S Manufacturing for Your Dip Brazing Needs?

Since 1968, H&S Manufacturing has been a trusted partner for precision aerospace fabrication. Our aluminum dip brazing services are backed by ISO 9001:2015 and AS9100 certifications, ensuring every project meets the highest quality standards. We are ITAR-compliant and authorized to handle Covered Defense Information (CDI) as a secure and reliable partner for defense-related aerospace programs.

We provide more than just aerospace dip brazing. Our team manages the entire production process from component fabrication to final assembly and testing, so customers have a single-source solution. This integrated approach reduces lead times, streamlines communication, and provides complete accountability.

H&S Manufacturing combines technical expertise, modern equipment, and a commitment to integrity to deliver assemblies that meet exact aerospace specifications. Whether your project requires precision dip brazing for avionics, hermetically sealed aerospace components, or large-scale aluminum assemblies, we have the capabilities to meet your needs.

To learn how our aerospace brazing services can support your next project, contact us or request a quote today.

Get a Custom Aerospace Brazing Quote

FAQs About Defense & Government Robotic and Remote Operation Device Manufacturing

For many military, defense, and government applications, especially those that involve drones, UAVs, and tracked or wheeled ground robots, as well as other equipment operated remotely, parts and assemblies have extremely tight tolerances and strict material requirements. Precision manufacturing and familiarity with government military standards are critical in these cases, to ensure that components fit and function correctly for reliable performance in harsh field conditions.

For over 50 years, H&S Manufacturing Co. has delivered precision manufacturing for highly regulated industries, including the government and military. Here we’ll answer some common questions about precision manufacturing for drones, robotic equipment, and remote operation devices.

Military and Government Drone and Remote Control Device Manufacturing FAQs

How H&S Manufacturing Delivers Precision Robotics Components

Robots are reshaping manufacturing floors and redefining what’s possible in terms of productivity, precision, and consistency. From welding car frames to assembling microchips, industrial robots have become essential to nearly every modern production line. However, while these machines may appear futuristic on the surface, their performance ultimately depends on something far more fundamental: the quality of their internal components.

Each robotic movement relies on precision-engineered parts that must operate flawlessly day in and day out. That’s where H&S Manufacturing steps in. With over five decades of experience and deep expertise in industrial automation and robotics, H&S delivers the machining, fabrication, and custom builds that keep the world’s most advanced manufacturing robots running smoothly.

Key Structural & Mechanical Robotic Components

Industrial robots are complex systems composed of interdependent mechanical, electrical, and control subsystems. Below are some of the key structural and mechanical components from H&S Manufacturing that bring these systems to life.

Robot Arm / Manipulator

This is the primary moving structure of the robot. It is often modeled after a human arm with multiple joints or axis points. For the arm to perform precise, repeatable tasks, its components, like links, joints, and bearing housings, have to be machineKey Structural & Mechanical Robotic Componentsd to exact specifications.

Even the slightest deviation in tolerances for these components can result in motion errors or misalignment. H&S Manufacturing delivers the tight tolerances required (up to +/- .001 inches) to ensure accuracy and smooth movement.

End Effectors

This is the robot’s “hand,” which is customized for specific tasks such as gripping, welding, or painting. Fabricating grippers, mounts, and interface tools demands both flexibility and precision. H&S supports this need through custom box builds and sheet metal fabrication tailored for each end use.

Drive Systems

These are the powerhouses behind robotic motion. Precise machining of gears, motor mounts, and shafts minimizes backlash and ensures smooth power transmission. H&S’s capabilities are ideally suited for fabricating these high-performance components that reduce wear and maximize efficiency.

Structural Elements / Bases

Every robot needs a solid foundation, as instability can compromise its operation. H&S fabricates structural bases, mounting plates, and protective enclosures that provide the alignment and vibration dampening necessary for optimal performance.

Other Components

Other critical parts H&S Manufacturing can provide include:

• Controllers. These are the “brain” of the robot. H&S can provide custom box builds for controller enclosures.
• Wiring & cabling. Both are vital for power and communication. These are supported by H&S’s custom cable management solutions.
• Sensors. These offer feedback on positioning and environment. H&S is able to create precision mounts to ensure proper sensor alignment.
• Sealing & gaskets. These are critical to protect internal electronics. H&S produces custom form-in-place gaskets for moisture, dust, and EMI protection.

How H&S Manufacturing Delivers Precision-Engineered Robotic Parts

H&S Manufacturing’s reputation in the industrial robot industry is built on quality, precision, and adaptability. Here’s how we support industrial manufacturing robots at every level:

• Custom manufacturing expertise for robotics. H&S delivers precision-manufactured components specifically designed for robotic systems. Since 1968, the company has maintained a standard of excellence across industries by partnering with leaders in industrial automation and robotics.
• Precision machining. Operating an ISO 9001:2015 and AS9100-certified, AS9146 compliant, ITAR-compliant facility, H&S uses advanced CNC machining capabilities to craft complex robotic parts, including milling, boring, drilling, and tapping.
• Sheet metal fabrication. From robot bases and enclosures to mounting plates and guarding panels, H&S fabricates critical sheet metal components using laser cutting and advanced welding techniques. Our work supports both function and form in robotic systems.
• Value-added services. H&S enhances robotic component performance through heat treating, powder coating, plating, and complete mechanical assembly. These finishing touches improve durability and reduce lead times for integrators and OEMs alike.

Ready to Elevate Your Robotics? Contact Us

The components of industrial robots may be hidden beneath sleek exteriors, but their role is anything but minor. At H&S Manufacturing, we combine industry-leading machining and fabrication capabilities with a deep understanding of industrial robotics to deliver parts that power innovation at scale.

Ready to take your robotic systems to the next level? Contact us or request a quote to get started.

Elevating Drone Performance: The Role of Precision Components

Drones have become indispensable tools in government, defense, and industrial operations. From inspecting bridges to supporting tactical missions and streamlining warehouse logistics, they now play a critical role across sectors. However, advanced drones require more than advanced electronics; they rely on precision-engineered components at every level.

H&S Manufacturing is at the forefront of this innovation, supplying reliable, high-performance drone components that enhance the capabilities of modern unmanned aerial vehicles (UAVs).

Why Precision Components Are Critical for Drone Performance

Optimized Flight Dynamics

Even minor imperfections in shape, balance, or alignment can disrupt a drone’s aerodynamics. Precision-engineered drone components help reduce vibration, improve stability, and maintain control to ensure smooth, responsive flight.

Durability in Demanding Environments

Drones often operate in harsh conditions, including vibration, temperature extremes, moisture, and corrosive environments. Precisely machined and fabricated drone components made from high-performance materials are essential to resist wear, prevent fatigue failures, and extend operational lifespan under continuous stress.

Reliable Data and Payload Integrity

Sensitive parts like LiDAR, thermal imagers, and cameras require secure, vibration-resistant mounting. High-precision drone components help to maintain proper alignment and vibration isolation, ensuring consistent data accuracy during flight—even in challenging, high-movement applications.

Safety and Mission Success

In critical operations, from government surveillance drones to industrial inspections, even one component failure can cause mission disruption or property damage. Reliable, precision-built parts help prevent failure points, ensuring safe, predictable operation in high-stakes environments where performance cannot be compromised.

Long-Term Cost-Effectiveness

While precision drone parts and components may cost more upfront, they deliver better lifecycle value. Durable, high-quality parts reduce repair frequency, lower maintenance needs, and prevent expensive mission failures, making them a smart long-term investment for demanding UAV applications.

Real-World Drone Applications: Transforming Government & Industry Operations

Drones are redefining operations across sectors by enabling faster, safer, and more detailed monitoring in areas that are hard to reach.

Government Sector Applications

• Infrastructure Monitoring. Used to inspect bridges, pipelines, power lines, and dams to prevent structural failures and improve public safety.
• Defense Operations. Used for surveillance, tactical support, and border security.
• Public Safety. Deployed in search and rescue, wildfire response, and law enforcement surveillance.

Manufacturing and Industrial Applications

• Drone Infrastructure Inspection. Used to examine machinery, factory floors, and production areas, especially in hazardous or hard-to-reach environments.
• Drone for Warehouse Operations. Supports automated inventory tracking, reducing human error and improving logistics.
• Quality Control. Helps identify product defects more efficiently through high-resolution imaging and repeatable inspections.

H&S Manufacturing: Your Trusted Drone Component Manufacturer & Supplier

High-performance drone systems require components that meet the strictest quality and precision standards. For over five decades, H&S Manufacturing has supported this need by delivering custom-manufactured parts built to exact specifications.

Founded in 1968, H&S has a long-standing reputation for quality and consistency. Our capabilities include:

We work with a wide range of materials essential to drone construction, including aluminum, stainless steel, copper, and plastics. Our advanced equipment allows us to maintain tolerances as tight as ±.001 inches (±.0254 mm), supporting complex geometries and reliable performance.

H&S operates an ISO 9001:2015 and AS9100 certified facility that operates a robust FOD prevention program that is AS9146 compliant. We are also ITAR-compliant and meet DFARS Clause 252.204-7012, ensuring full compliance with quality and cybersecurity requirements for defense-related applications.

Elevate Your UAV Project With H&S Manufacturing

The growing use of drones across government and industrial sectors calls for components that meet the highest standards of precision and reliability. H&S Manufacturing supports this need by supplying the custom-engineered parts behind today’s most advanced unmanned systems.

Contact us or request a quote to learn how our custom manufacturing capabilities can support your next drone project.

Materials Used in FIP Gaskets

H&S Manufacturing Co. provides form-in-place (FIP) gaskets, an exceptional alternative to conventional molded or die-cut solid gaskets. FIP gaskets ensure 100% contact with substrates, creating a reliable seal that can shield against electromagnetic interference (EMI), dampen vibrations, and effectively block moisture and dust.

FIP gaskets can also minimize inventory needs, reduce lead times, and support precision placement of intricate gasket patterns in custom applications. This allows for more compact form factors, supporting miniaturization trends in electronics manufacturing. When dispensed, FIP liquid gaskets are opaque and typically thicker than other adhesives, curing into flexible or rigid solids. They are available in one- or two-component formulations, including:

• Acrylated urethanes
• Anaerobics
• Polyurethanes
• Silicones

The materials used in FIP liquid gaskets include rubber and advanced composites. These materials are gaining wide acceptance and starting to replace room temperature vulcanizing (RTV) sealants and traditional extruded, molded, and die-cut gaskets. FIP gaskets have a proven reputation for delivering high performance and cost-effectiveness across a wide range of manufacturing industries and commercial applications, including:

• Aerospace
• Automotive
• Government & Military
• Medical
• Commercial Electronic

Here, you’ll learn more about the materials used in FIP gaskets and their common applications.

Conductive Materials for FIP Gaskets

Electrical conductivity is a primary consideration for many applications that utilize FIP gaskets. To enhance this property, FIP gaskets consist of a conductive material and a base material. The conductive material is mixed into the base material to form a paste. Commonly chosen conductive materials include:

The three main types of base materials are:

• Silicone
• Fluorosilicone
• Synthetic rubber

Selecting the proper base and conductive materials for FIP gaskets can prove challenging, since each material has different properties. However, it is possible to rule out several options based on the following key considerations:

• Budget. Using the project budget as the primary focus allows users to rule out silver for use as a conductive material. While the material offers high electrical conductivity, it is considerably more expensive than graphite and nickel.
• Performance characteristics. Understand the key properties of each base material and what your application needs. For example, fluorosilicone demonstrates superior resistance to oil and fuel, while silicone is more resistant to high temperatures. Synthetic rubber is less expensive than the other materials but cannot withstand the elements, making it unsuitable for outdoor applications.

Material and Equipment Trends in FIP Gaskets

FIP liquid gasket manufacturers are developing materials designed to improve the performance and EMI blocking of electronics, such as:

• Automotive: infotainment chassis shielding, radar, autonomous driving systems
• Telecommunications antenna: radio, RRU, AAS, AAU
• Data communications: high-speed connectors, optical transceivers

These conductive elastomer gaskets are compatible with metal, plated, and plastic substrates such as enclosures and packaged electronic assemblies. Some FIP gasket producers are offering specialty silicone gaskets with IP68 ratings and fluorosilicone gaskets approved for aerospace applications.

Recent advances in automated FIP gasket dispensing technology promise to reduce material waste and labor costs while speeding up the production process. Precision dispensing equipment can accurately place beads as small as 0.3 mm tall. Room temperature curing also eliminates the need for additional heat curing equipment, further minimizing production steps and saving costs.

Applications

FIP gaskets are typically utilized for high-performance applications where the following properties are necessary to provide lasting results:

Oxidation inhibitors are also integrated into some materials to extend their service life.

FIP Gaskets from H&S Manufacturing Co.

Since 1968, H&S Manufacturing Co. has provided custom manufacturing solutions with an unwavering commitment to quality and the highest standards of excellence that meet or exceed our customers’ expectations. Our high-quality form-in-place gaskets and dispensing equipment serve many different industrial and consumer products, such as racks, computer chassis, and testing equipment.

We use 3-axis CNC robots to dispense silicone-based EMI shielding gaskets for customers in these industries:

Our FIP gaskets are compatible with plastic, plated, and metal substrates and comply with various industry standards and specifications, including:

At H&S Manufacturing, we can accommodate any size project, from prototypes to high-production volumes. Our experienced and dedicated staff take all the necessary steps to ensure quality results in product appearance, value, delivery, reliability, service, feedback, cost reduction, and innovation.

Contact us today to learn more about our form-in-place gasket products and services.

Why FIP Liquid Gasketing Is Replacing Traditional Sealing Methods

Die-cut and molded gaskets have been the conventional sealing solution for many years, but they have several limitations that may make them unsuitable for certain applications. For example, traditional gaskets require manual assembly and are often labor-intensive to fabricate, often with costly dies or other tooling. They risk burdening inventory and offer limited customization for complex geometries or irregular surfaces. Variations in fit and compression can also lead to inconsistencies in EMI shielding and sealing. 

As a result of these potential drawbacks, you may want to use form-in-place (FIP) gaskets instead. This more recent industrial sealing advancement allows manufacturers to dispense the gasket material in liquid form and cure it in place. Here, we’ll explore the benefits of using FIP vs. traditional gaskets for various applications.

How FIP Overcomes These Challenges

Compared to traditional gasketing, FIP liquid gasketing benefits industrial applications in several key ways:

• Automated, precision application. One of the main benefits of FIP gaskets is their use of automated dispensing for application, which allows for more precision than traditional gasketing. Automation helps prevent human error while allowing for more repeatability and efficiency.
• Compatibility with various substrates and designs. Another advantage of FIP gaskets is that they conform to nearly any size and shape, regardless of complexity. You can also dispense them easily on nearly any substrate, including plastics, metals, and plated materials.
• Reduced assembly and labor requirements. Automated FIP gasket application also eliminates manual tasks, subsequently shortening the assembly process. As a result, operations benefit from reduced labor expenses and increased overall productivity.
• Simplified supply chains and inventory. FIP gasketing reduces inventory needs through sole reliance on dispensing systems and raw materials, keeping physical inventory and supply chains simpler and more efficient to manage.

Cost & Efficiency Comparisons

Working with FIP gaskets also comes with the following operational efficiency and cost-saving benefits compared to traditional gaskets.

Reduced Tooling and Setup Expenses

Unlike traditional gaskets, FIP gasketing doesn’t require custom-fabricated molds or dies that could otherwise add more tooling costs. Instead, FIP gaskets rely on programmable dispenser systems that eliminate the need for additional tooling and setup costs.

Enhanced Scalability and Efficiency

Because they rely on manual processes, traditional gasketing systems can decrease the efficiency of production through various bottlenecks along the assembly line. FIP gasketing, on the other hand, maintains efficiency through automation, keeping production lines moving. In addition, the automation makes FIP gasketing more scalable based on changing production needs.

Lower Cost of Ownership

The superior quality you can get with FIP gaskets helps reduce the need for repairs and replacements due to leakage and other issues. These gaskets offer a better fit, which means more long-term reliability and durability than their traditional counterparts. Ultimately, this lowers the total cost of ownership.

Learn More About the Future of Sealing Technology

As the sealing technology evolution progresses, automated FIP gasketing is emerging as one of the most innovative solutions in the industry. This comparison of FIP vs. traditional gaskets reveals numerous areas where FIP gaskets outperform traditional ones, including reduced manual labor, increased customizability, more scalability, and enhanced efficiency.

At H&S Manufacturing, we have the resources and expertise to help optimize your industrial sealing operations with custom capabilities. Our custom form-in-place gasket solutions serve the automotive, aerospace, telecommunications, military, medical, and many other industries. In addition to custom form-in-place gasket dispensing, we offer precision machining, sheet metal fabrication, laser cutting, custom box builds, secondary and finishing services, and more.

Request a quote today to discuss your specific project needs with our team of experts.

Building Charging Systems for Electric Vehicles

Charging systems are used in many different settings to power electric vehicles. They can be built for a number of purposes, from overnight charging to high-speed charging for long-distance travel. This blog will discuss the growing need for efficient EV charging systems and detail the types of EV charging systems users can choose from.

Importance of Charging Systems for Electric Vehicles

As the number of electric vehicles on the road increases, so does the need for efficient EV charging systems. Having reliable access to charging systems provides added convenience and flexibility for EV owners. It also removes fossil fuels from the equation, which is essential to achieving long-term sustainability goals and supporting the continued adoption of electric vehicles.

Types of EV Charging Systems Explained

When building charging systems for electric vehicles, there are two primary challenges to address. The first is logistics, with many consumers expressing a desire for more charging stations. As of now, there are far fewer charging ports than are needed to achieve carbon-free energy systems by 2050.

The second issue involves concerns regarding travelable distance with each charging cycle. Currently, several main types of charging systems are available for electric vehicles:

• Level 1. These are slower systems that many homes use to charge vehicles overnight, with each hour of charging supplying enough power for a five-mile driving range.
• Level 2. Many public facilities and workplaces use these faster chargers, which supply enough charge every hour for 25 miles of range.
• Level 3. Ideal for gas stations and other locations accommodating long-distance travel, these are the fastest chargers, supplying sufficient power for up to over 200 miles of range after 30 minutes of charging.

Building high-quality electric vehicle charging stations promotes a strong charging infrastructure that can meet the varied needs of EV vehicles.

What Makes up an EV Charging System?

Electrical vehicle charging systems rely on a number of components, connectors, and systems:

Power Sources and Compatibility

Charging systems need to be able to draw power from reliable sources and must work with multiple types of EVs. The electric grid is a primary source for EV power. Power lines in the grid transmit electrical power to charging stations, transitioning the power into direct current (DC) electricity to supply the charge.

Due to the external installation of many charging stations, power sources often require an EV power distribution cabinet. This provides ongoing protection from harsh weather and other environmental conditions.

Connectors and Cables

Charging systems typically use one of two types of connectors:

• Alternating current (AC) connectors for slower chargers running on AC
• DC connectors for faster chargers using DC

In North American markets, you can obtain two primary charger plug types, including CCS 1 for DC charging and SAE J1772 (Type 1) chargers for Level 1 and 2 AC charging.

Software and Monitoring Systems

These systems also require management and monitoring tools to maintain efficient energy use. Innovations in software allow for intelligent infrastructures that effectively track energy usage. For instance, systems may use cloud-based solutions that offer features like remote real-time monitoring and management or in-depth data analytics. These solutions help meet drivers’ needs while also optimizing the user experience.

Site and Power Requirements

EV charging systems must perform according to several critical requirements:

• Power Requirements. Different electric vehicles will require varying power levels. While most home chargers use up to 7,200 watts (W), this fluctuates based on the charger and charging mode.
• Site Setup Needs. While indoor installation will provide better protection from the elements, some may prefer outdoor-rated systems for parking lots and other exterior sites. Regardless of the placement of charging systems, they must connect to a nearby building’s power supply.
• Safety Compliance. Chargers also need to be dependable and safe, from the conductor used during installation to the amount of overhead space they provide. It’s important to consult the manufacturer’s instructions for details about proper usage, storage, and charging, as any unauthorized modifications could render charging systems unsafe.

Charging Systems for Electric Vehicles at H&S Manufacturing

Selecting the best charging station for a given area ultimately depends on build and charging requirements. AT H&S Manufacturing, we are familiar with the evolving charging needs of our customers. We provide custom metal fabrication services for a variety of applications, including automotive, aerospace, electronics, and medical devices.

For help with an EV charging system build, turn to the experts at H&S Manufacturing. Request a quote today to learn more about our capabilities and get started on a custom build.

Emerging Market of Electric Vehicles

As the automotive industry continues to adopt electric vehicles (EVs), PwC analysts predict the market could expand almost tenfold by 2030. This projection is supported by an increase in consumer interest and the willingness of automakers to go all-in for the expansion of the U.S. electric vehicle market.

Substantial government funding has also played a significant role in the growing EV sector. The 2021 Infrastructure Investment and Jobs Act allocated $7.5 billion to EV charging infrastructure, and the Inflation Reduction Act introduced tax credits for those purchasing new and used commercial and passenger EVs.

Considerable investments are still needed to build a national charging network for the estimated 27 million U.S. electric vehicles expected on the roadways by 2030. While such an undertaking will prove challenging, it is necessary to ensure the future viability of EV transport. U.S. manufacturers throughout the EV supply chain—from battery manufacturers to metal part fabricators—are ramping up production of EV components and charging infrastructure parts to support these electrification trends.

Electric Vehicle Market Trends

PwC’s recent study highlights the main U.S. electric vehicle market trends to expect in the coming years. Since 2021, over 20 electric vehicle charging startups in the U.S. and the EU have been acquired, many by major energy companies. In the past four years, at least five EV businesses have gone public through special purpose acquisition companies (SPACs), and funds raised from initial public offerings (IPOs) have given these businesses the cash to acquire other EV businesses.

Analysts expect the workplace segment to be the fastest-growing charging segment, with anticipated growth from around 0% of the total EV market to approximately six million charge points (or 17%) by 2030. Multi-unit residential apartment buildings are another fast-growing sector, also expected to expand from nearly 0% to 17% of the market by 2030. This rapid growth will task construction and engineering firms with integrating charging points in new and existing garages and parking lots.

Meanwhile, EV sellers (like dealerships and OEMs) will dominate 70% of the market for residential chargers in single-family homes. Integrators and installers are predicted to serve 80% of all other EV charging market segments.

Key Takeaways From the EV Supply Equipment Market

The electric vehicle supply equipment (EVSE) market has the potential to grow at a 15% compound annual growth rate (CAGR), from $7 billion in the early 2020s to $100 billion in 2040. Here are some insights into the future of the following key areas in the EVSE market.

Hardware Manufacturers

Product developers of EVSE face high upfront costs for manufacturing, research, and development. These costs are necessary to remain competitive in the EV market, and hardware providers can expect considerable long-term gains from the rising demand for EVSE services and products.

Software Providers

To generate a revenue stream from EVSE applications, software companies must develop customer-facing and back-end solutions. Profit margins are expected to increase as fleet management solutions are integrated into existing on-the-go systems.

Installation Services

Despite being a lower-margin business, installation services are expected to grow quickly as the need for public charging infrastructure continues to increase. As federal government funding gets disbursed, installation service companies may find relief from the reduction in new installations and start experiencing a significant increase in retrofitting outdated infrastructure.

Charge Point Operators (CPOs)

Today, many charge point operators (CPOs) are burdened by low utilization rates and hefty capital expenditures. While these businesses are in it for the long-term payoff, a successful CPO business model will be challenging to execute. However, companies that manage to ride the wave may reap substantial dividends when charging stations become as common as gas pumps.

As EV adoption rates become mainstream, integrated charge point operators (CPOs) will have the chance to improve their bottom lines by bundling offerings such as:

• EVSE Financing
• Operation
• Utility Charging
• Maintenance

Creating Jobs in the EV Market With the Infrastructure Act

The $1.2 trillion in funding from the Infrastructure Investment and Jobs Act aims to tackle the following challenges facing the expanding U.S. electric vehicle market:

1. Address the repair backlog in transport systems
2. Modernize and secure existing infrastructures
3. Support the transition to a clean economy

Part of the funds from this long-term federal investment includes the expansion (by thousands of miles) of the electrical grid’s high-voltage transmission network across the U.S. This expansion will help facilitate the efficient delivery of renewable energy through transmission corridors marked high priority, supporting the nation’s transition to an integrated grid that can help regions share power and control electricity shortages and pricing volatility.

The Infrastructure Investment and Jobs Act comprises a variety of grants, loan financing programs, and technology development incentive payments that businesses need to understand to take full advantage of the available offerings while anticipating the reporting obligations and conditions that come with them.

Automotive Metal Fabrication by H&S Manufacturing

To keep pace with the rapid acceleration of EV adoption in the U.S., EV charging infrastructure builders need to scale up their operations accordingly. H&S Manufacturing has the expertise and equipment to help EVSE businesses meet the challenging supply needs of EV charging stations. Since 1968, H&S Manufacturing has provided custom metal fabrication services for the automotive, electronics, medical device, aerospace, defense, and other critical industries. Our experienced team can help you select the best material for your application and deliver high-quality custom components for your project.

Contact us today to connect with a team member about the specific demands of your EV project.

Sustainment: Building a Nation of Builders

Building a sustainable future means building sustainable practices across the U.S. manufacturing industry. Sustainment is a public benefit corporation dedicated to fostering this mission.

We make sure that American manufacturers have the technological tools they need for profitable manufacturing, streamlined supply chain management, and long-term partnerships with defense, federal, and state organizations within the government.

Public benefit corporations stand apart from other corporations in their singular commitment to public benefit. At Sustainment, our team’s mission is to support yours. Learn more about how we can help you meet your organization’s goals and strategically collaborate with suppliers, clients, and business partners.

What Sets Sustainment Apart?

Sustainment helps manufacturing organizations implement successful domestic manufacturing projects. Our next-generation technology platform connects local and regional suppliers with manufacturers, building a strong manufacturing sector that lowers our country’s geopolitical risks on an international front.

Mission-Driven Approach

Our mission-driven approach centers on domestic manufacturing capabilities.

When you choose to incorporate Sustainment into your processes, you gain access to our unique mission, technology, and cost management tools. We help our clients harness these technologies to find continued success in an evolving industry.

Streamlined Manufacturing

We build and develop the technology manufacturers need to simplify production and create profit. Our platform cuts down on waste and time-intensive processes, increases efficiency across key processes, and creates cleaner, faster workflows from start to finish.

Profitability and Cost-Effectiveness

Trimming down costs and achieving profitability requires the right tools. Sustainment is focused on helping US manufacturers reach their financial goals by implementing cost-effective processes and partnerships while maintaining high-quality production standards.

Reimagining American Manufacturing

Creating a strong core of American manufacturing is important to Sustainment’s mission, as well as contributing to a sustainable domestic production pipeline and creating economic resilience.

Our team is committed to transforming the American manufacturing landscape by creating a secure, streamlined ecosystem that fosters collaboration, fast transactions, and progress.

Hyperconnected Ecosystem

Sustainment’s platform supports security through connection. Local, regional, and nationwide suppliers and manufacturers can easily find qualifying contacts, negotiate on project specifics, and complete transactions with minimal waste or delays. We facilitate instant and mutually beneficial communication between producers and commercial and defense organizations.

Secure Transactions

Financial security is a growing concern for every sector. Creating secure payment channels for every vendor can also be highly manual and prove burdensome for manufacturers waiting to begin their work.

Sustainment’s secure transaction platform creates a space where buyers, suppliers, and government organizations can securely complete transactions and streamline procurement. Together, we are building a more efficient supply chain.

Core Values

Since Sustainment is a public benefit corporation, our mission and values are at the core of what we offer. We operate based on these core values:

• Integrity. All of our endeavors and services are transparent, and we operate with a strict code of honor.
• Innovation. We are continuously innovating to help our clients access relevant technologies.
• Expertise. Our team members have years of experience in both technology and manufacturing.
• Service. We’re committed to supporting our clients so they can continue to serve theirs.
• Commitment. Our mission is central to every decision we make.
• Collaboration. We foster collaboration between business entities, integrating technology and products the American manufacturing industry needs to thrive.

Join the Mission

At Sustainment, we are focused on fostering the ongoing success of manufacturing in the U.S., providing tech solutions that empower our manufacturers. As the industry evolves, so do our efforts to support the larger industry.

If you’re also committed to the growth of the American manufacturing industry, reach out today to join Sustainment. We’re currently looking for individuals with technology or manufacturing expertise who are dedicated to furthering our mission.