Custom 3.5kW Portable EV Charger for Automaker

Project Overview

A leading new energy vehicle manufacturer in Southeast Asia launched a new series of pure electric models and required factory-fitted portable charging kits as standard accessories delivered to end vehicle owners.

Previously, the automaker purchased portable chargers from other suppliers. Those products suffered unstable quality, poor vehicle compatibility and large batch-to-batch variations, resulting in high after-sales complaints from car owners and failing to meet the quality standards for OEM automotive parts.

Therefore, the client sought a long-term deep customisation partnership with an original equipment manufacturer capable of automotive-grade quality, stable mass delivery, custom design & development and full brand support services. The goal was to develop a tailor-made portable charger exclusively matching their vehicle models.

This project adopted a fully offline portable design. There is no internet connection or OCPP backend function. The product features simplicity, stability and durability for emergency home charging scenarios.

Core Project Requirements

Product Specification: 3.5kW portable EV charger, Type 2 EU plug, adjustable current, plug-and-play.

Product Positioning: OEM emergency charging kit bundled with new vehicles.

Customisation Requirements: Independently developed exclusive housing (not generic public mould), custom boot-up UI text, unique SN code for each unit for traceability.

Certification: Full CE EN61851 certification to satisfy Southeast Asian import and after-sales filing requirements.

Performance: Full protection against over-current, over-voltage, under-voltage, over-temperature and earth leakage, compatible with local fluctuating grid conditions.

Function: Fully offline operation, no server or network access, simple structure and low failure rate.

Packaging: Custom brand colour boxes, user manuals and carton marking / white label solutions.

Our Customised Solution

Supported by our in-house R&D team (for both hardware mainboard and mechanical appearance), in-house SMT workshop for PCBA assembly and independent testing centre, we implemented comprehensive optimisations to meet the strict OEM standards and offline home charging scenarios.

1. Full in-house R&D for appearance and mainboard

Our R&D team independently developed the hardware circuit design and mechanical housing. No generic public mould is used. Custom boot-up interface together with one-unit-one-SN traceability system is implemented for the automaker’s after-sales management, creating differentiated product features.

2. Special optimisation for fully offline version

Redundant smart connectivity modules are removed. We focus on stability and low failure rate while retaining complete electrical safety protections. This avoids common pain points caused by network modules such as high failure rate and complicated compatibility, perfectly matching the OEM bundled accessory application.

3. Automotive-grade mass quality control with in-house production & testing

PCBA boards are processed and assembled in our own SMT workshop. Our internal testing centre runs dedicated inspection procedures for automotive orders, including accelerated ageing tests and grid fluctuation simulation tests. Batch colour deviation and performance inconsistency are strictly controlled to maintain high product uniformity and meet OEM component standards.

4. Delivery of full set of custom technical documents

We provide branded versions of user manuals, specifications, test reports and certification files to support the client’s product registration and after-sales system integration.

5. Long-term stable delivery for vehicle OEM matching

Dedicated production lines and quality inspection teams are assigned to guarantee stable lead time, synchronised with the automaker’s new vehicle mass production schedule.

Project Achievements

We successfully developed the exclusive portable charging kit for this leading Southeast Asian EV maker, and the product became the standard OEM accessory across their new vehicle lineup.

The fully offline stable design greatly reduced after-sales failure rates and eliminated industry pain points of poor compatibility and unstable performance found in generic off-the-shelf chargers.

Through deep cooperation on custom appearance development, the client avoided heavy R&D investment. They quickly launched differentiated bundled charging products and shortened the time-to-market of their new EV models.

Both parties established a long-term strategic OEM partnership to achieve consistent mass supply.

Key Strengths

✅ Full in-house R&D for mainboard hardware & mechanical appearance

✅ In-house SMT workshop & PCBA assembly

✅ Self-owned testing centre for reliable quality control

✅ Stable fully offline portable solution with low after-sales failure

✅ Automotive-grade batch consistency control

✅ Exclusive custom housing (non-public mould)

✅ One-unit-one-SN traceability system

✅ Complete certification & custom technical documentation package

✅ Proven capability for long-term OEM mass delivery