EV/AV - Electric Vehicles
Precision, Control, and Cost Efficiency Solutions
The electric and autonomous vehicle revolution demands more than innovation—it requires smarter, faster, and more cost-effective manufacturing. KALLER supports this transformation with a variety of solutions:
- Flex Cam: Advanced forming and cutting tool
- KF2 Controllable Gas Springs: Advanced forming gas springs
- Standard Tool & Die Gas Springs
- Accessories: that support lightweighting
Advance Your Operation
Our advanced cutting and forming solutions help leading manufacturers reduce production complexity, enhance part quality, and boost throughput, with technologies like the Flex Cam and Controllable Gas Springs (KF2) delivering high-precision, space-efficient, and cost-effective performance for producing modern vehicle components such as fenders, battery enclosures, and charge port openings.
Optimize EV/AV Manufacturing with KALLER
Flex Cam Technology
KALLER Flex Cam enables:
- 360° die positioning and multi-functionality in a single tool
- Controlled force and high-precision cutting & forming for components like charge ports
- Space-efficient design ideal for modern dies
- Up to 2 million cycles without maintenance, minimizing downtime
- Capability to punch upwards at negative angles for flexible die design
Manufacturers can simplify their stamping operations—cutting both EV and non-EV components in the same die, reducing tooling costs, increasing speed, and improving part quality.
See our Case Study with the Flex Cam in action for an EV charge port.
KF2 Controllable Gas Springs
KALLER's KF2 Gas Springs bring unmatched control and flexibility to EV/AV forming operations:
- Remotely adjustable pressure to fine-tune blank holder force
- Multi-operation capability to perform more with fewer tools
- Enhanced part quality by preventing wrinkles, thinning, and splits
- Locked force at bottom dead center for clean panel release
- Lower maintenance and reduced tool wear over time
Whether forming complex parts or balancing lightweight components, KF2 gives manufacturers precise control for every stroke—leading to better parts and faster production cycles.
See our Case Study with the KF2 improving precision in an operation.
HDP - Protection in Hot Stamping
The HDP - Heavy duty protection is a protective cover for gas springs in dirty or contaminating environments like in Hot Stamping, which is sometimes utilized for lightweighting in electric vehicle operations.
- Prolong gas spring service life
- Reduce downtime
- Increase operation throughput
- Reduce costs from unnecessary maintenance and replacements
See our blog post about improving Hot Stamping Operations with HDP
Standard Gas Springs
KALLER is the original gas spring leader in the Automotive Tool & Die industry, and for good reason.
- Large Assortment: An exceptionally large variety of standard gas springs.
- Trusted: world wide by all the major OEMs by being specified in their company standards.
- Quality & Reliability: Developed and manufactured to top quality standards that you can rely on.
- Safety: With advanced Safety Features you can protect your equipment, operation, and most importantly your teammates.
KALLER’s cutting-edge solutions aren’t just built for today’s vehicles—they’re built for what’s next. Partner with us to advance your EV/AV production capabilities and stay ahead in the race toward electrification and autonomy.
