Case Study

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How ISC Helped Tesla set the foundation for their EV charging adaptors and mating plugs.

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  • The Initial start of the project was for consulting on the development of EV charging adapters and mating plugs, which started on Feb 2, 2011. At that time, Tesla stock price was $23.89.
  • Fourteen months of audits, evaluations, and discussions led to the kickoff of the mold tools which we developed in-house. The initial order was for five molds on April 23, 2012
  • The first adapter shipped on July 27, 2012.
  • ISC previously worked and developed EV chargers for other customers and worked through the UL process, but these were 100% custom and something entirely new to the industry.
  • The parts were developed under high scrutiny from all quality aspects. Six Sigma methodology that uses statistical analysis to reduce process variation was applied to all aspects of the assembly process. Inspection, testing, and product traceability were each essential to deliver a highly reliable product that was also cosmetically flawless.
  • By bringing the product to ISC, they were able to make these mechanical (capped) adapters more aesthetic, durable, and tamper-resistant by over-molding them.
  • January 7, 2013, ISC shipped the first wall plug and, in less than four years, manufactured and shipped over 190,000 plugs. Every plug came standard with a 5-15 and 14-50 adapter, but multiple other NEMA variations were available.

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Tesla approached ISC with a consulting project to develop EV charging adapters and mating plugs that were not only reliable but also met the aesthetic standards of the Tesla vehicle.

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ISC and Tesla worked together for 14 months to develop mold tools, which then produced adapters with the utmost quality and efficiency.

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After setting a high standard at ISC, Tesla transitioned production offshore to support its exponential growth.
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No matter what phase your project is in, we can partner with you to design and manufacture complex assemblies with custom overmolding. Simply submit a project and one of our experts will be in touch with you within 24 hours as we review your project.

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