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How its EV chargers are made
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- DeepHorus
Lectron, a leading supplier of EV charging adapters and home chargers, has opened its factory in China to reveal the rigorous manufacturing process behind its products. The company, which supplies adapters to automakers like Ford, GM, and Mercedes-Benz, recently launched the NEXUS, its second-generation Level 2 home EV charger. A tour of the facility provided insight into how Lectron maintains quality and safety standards that meet both consumer and automotive industry requirements.
Founded as a direct-to-consumer brand through retailers like Home Depot and Amazon, Lectron has quietly grown into an OEM supplier for over 15 global automakers. Each charging adapter contains about 60 components, and before an automakerâs logo is applied, engineers thoroughly vet Lectronâs manufacturing and testing processes. This means the company must satisfy some of the toughest quality requirements in the auto industry, not just its own standards.
CEO Chris Maiwald emphasized that quality and safety drive every stage of manufacturing, starting with design-phase problem analysis and process failure mode analysis. Every charger undergoes end-of-line testing for electrical performance, IP rating verification, aging chamber testing, and other durability checks. The company handles printed circuit board assembly (PCBA) in-house, using automated equipment to place tiny components with precision.
Each charger has a unique serial number, and every build step is digitally logged, including the quarter-turn of a screwdriver. Cameras capture internal layout images at multiple stages, allowing technicians to trace any issue back to its origin. This traceability ensures that if problems arise, they can be quickly pinpointed and resolved.
Durability tests include high-pressure water blasts, extreme heat exposure, drops, and being driven over. The NEXUS carries an IP66 weather-resistance rating, designed to withstand years of rain, snow, heat, and dust when mounted outdoors. Such rigorous testing has earned Lectron recognition: in April, The New York Times' Wirecutter named its portable Level 1 & 2 charger "the best J1772 charger to carry with you."
The NEXUS is available now as a non-wifi model, with a connected version expected in the coming months. Buyers can choose a NEMA 14-20 plug or hardwired installation, and both versions hold UL 2231, UL 2251, UL 2594, and UL 817 certifications. The NEMA 14-50 model also includes temperature sensors on each hot pin for added safety.
Lectronâs factory tour demonstrates how the company has become a trusted supplier in the EV ecosystem by combining automation with human oversight. As electric vehicle adoption grows, such manufacturing transparency may become a key differentiator for consumers and automakers alike. The NEXUS launch positions Lectron to capture more of the home charging market while maintaining its reputation for reliability.
