An electric vehicle manufacturer needed an expansion tank that could fit the remaining space and operating conditions of an almost-finalized powertrain compartment. Poor internal flow can create air bubbles entrained in vortices and impair degassing, while a mounting position that is too low can affect coolant replenishment and pressure balance. Developing a completely new product would be costly and could miss the vehicle validation milestone. A standard part, however, could interfere with the frame, wiring harness or coolant lines.

YCMinMax started with an existing product platform, selecting the tank design closest to the vehicle's packaging constraints and adapting its shape, connections and mounting features.

The design review checked coolant expansion volume, the system's venting path and blow-molded wall-thickness distribution together. The final assembly integrated the pressure cap, level sensor and vibration-isolation features so the customer could proceed directly to vehicle installation testing.

Sample validation used the customer's vehicle operating conditions as its boundary. It covered a 300 kPa static-pressure hold, burst testing above 600 kPa, more than 100,000 pressure cycles, high-temperature durability, thermal shock and three-axis vibration.

The validation scope included the tank body, fused regions, ports, pressure cap, sensor and mounting structure. Delivery followed confirmation that the complete assembly showed no leakage or structural failure under sustained thermal, pressure and vibration loads.