Low-cost, high-performance electric vehicles

To date, lightweight materials such as carbon fibre-reinforced plastics have been employed primarily in expensive high-performance cars. Developing a portfolio of lightweight materials with low carbon footprint for electric vehicles is the objective of the EU-funded project 'Enhanced lightweight design' (ENLIGHT).

The team is targeting medium-volume production of ultra-compact 4-seat passenger vehicles destined for market in the next 8-12 years. To meet their goals, scientists are working on the entire vehicle configuration, having divided up research to cover the major items contributing to overall weight. Design considers a front module, a central floor module, a front door, a sub-frame and suspension system, and an integrated cross car beam.

Highly advanced materials are under investigation, including thermoplastic matrix composites, fibre-reinforced composites, advanced hybrids and sandwich materials, and composites based on biomaterials and renewables. The team is taking a holistic view, considering performance, manufacturing, cost and life-cycle footprint. In addition, the project integrates important outcomes from other projects to increase the chances of success.

Researchers have delivered preliminary designs of the lightweight components for the five demonstrator modules. Numerous models have been developed to study noise and vibration, changes in stiffness due to electrical current and temperature changes, and micromechanical properties under loading cycles.

Materials development according to preliminary designs and simulations is proceeding for all modules. Scientists have already evaluated several manufacturing technologies. The assessment will also include an evaluation of the potential for integrating several functions into one component for less weight and space and greater simplicity in vehicle architecture.

ENLIGHT is combining simulations with experimental validation to spur the fast, efficient and reliable design and development of materials and processing solutions. Reducing the cost and environmental footprint of electric vehicles will lead to mass production and widespread market uptake. That, in turn, will significantly decrease the environmental impact of cars on the road.