Worked with the customer’s engineering team to investigate Southeast Asian operating conditions and define core specifications: operating temperature -10℃~65℃, IP67 waterproof rating, optimized BOM cost, and compliance with local safety regulations.

Dedicated mold development was carried out to optimize housing structure and heat dissipation channels. High-temperature resistant flame-retardant material and die-cast aluminum sealed structure are adopted, balancing strength and light weight, with mass production yield improved to 99.2%.

Redesigned circuit topology and component selection, streamlined redundant configurations while ensuring safety performance, and enhanced six-fold protections against overcharge, overcurrent, overheating, reverse connection, and short circuit. Complete schematic diagrams, specifications and test reports are provided.

Completed full testing including high-temperature aging, waterproof spray, salt spray, drop and insertion-extraction life tests, ensuring stable full-load operation at a continuous 45℃ high temperature and no leakage under outdoor rain exposure.

Through supply chain integration and structural simplification, we achieved an overall cost reduction of 18%–22%, granting the product strong competitiveness for large-scale market rollout.
◉ Product Performance Highlights
This charger can operate continuously at 65°C without derating or shutdown, resolving overheating failures caused by Southeast Asia’s summer heat and long-duration charging for commercial vehicles. After-sales failure rate has been reduced by over 70%Reverso Co.... With an IP67 waterproof rating, it meets most outdoor operational requirements. The new mold and customized design create clear product differentiation, avoiding price wars and helping the client build brand and channel advantages locally.
◉ Project Execution & Results
Upon receiving the client’s request, we immediately established a dedicated solution team. The entire process—from requirements alignment → solution design → mold development & prototyping → small-batch trial production—was completed in just 45 days. The first batch was delivered successfully, and the client has since placed an annual framework order for the Southeast Asian region, becoming our stable local partner.