The automobile industry has started choosing the best approach toward creating a lower-carbon future. Even electric vehicle makers want to make their production process eco-friendly. But, how would they improve sustainability without compromising resilience? Most EV brands have thought of replacing traditional materials with composite ones. Composites in electric vehicles will reduce the weight of automotive components, as it is a highly significant factor for running EVs.
The zero-emission cars- The future of the automobile industry
Running the diesel or petrol vehicles is the biggest concern about environmental issues. So, automotive engineers aim to create a greener world and reduce carbon emissions from vehicles. In some countries, governments have put a ban on selling new petrol vehicles. So, consumers are bound to buy zero-emission vehicles. This trend has resulted in rapid manufacturing of electric cars with composites
To increase the driving range of the vehicles, EV models have started replacing liquid fuel tanks. They have become more dependent on larger battery packs, which have a comparatively low weight. They comprise only 30% of the overall weight of the car. EV engineers want to save the mass of the vehicle model. They focus on using composites and advanced plastics materials. So, these carefully chosen materials will lower the weight while sustaining the integrity and strength of the vehicle.
Minimizing the car weight with advanced composites
The major reason for choosing the composite materials for modern electric cars is the minimal weight. Using lightweight composites is important, as EV batteries have a considerable weight. Their weight is 15% higher compared to traditional gas-operated engines. In fact, the car’s weight directly affects-
- The performance
- Energy efficiency
- Ease of managing vehicles
- Acceleration time
Advanced composites are highly advantageous for designing energy-efficient, high-performing EVs.
Which are the most commonly chosen composites in electric vehicles?
Let us make you familiar with composites suitable for designing the electric vehicle.
Carbon fiber
It is an ideal material for designing an electric vehicle. Polymers reinforced with carbon fibres ensure design flexibility, desirable weight, and appropriate strength. As the strength-to-weight ratio is good, the EV makers like to use carbon fibres for designing the car. So, when used for making the electric vehicle, the materials keep the model lightweight. Most commonly, carbon fibre is used for designing the chassis, body panels, and frames of an EV. The flexibility is advantageous in creating an aerodynamic vehicle. The exterior panels made from carbon fibres reduce air resistance ability. So, your car will be more energy efficient, and the driving range will be longer.
Fiberglass composites materials
Polyester resin and glass fibres are the main fibreglass composites used for different components of an EV. They are the best materials for designing-
- Doors and hoods
- Strong car body panels
- Other low-weight parts
Fibreglass composites are more affordable than carbon fibre. Some EV brands also use them for making interior parts like-
- Trims
- Panels
- Seats
Thus, the material will lower the overall car weight and boost performance. The EV engineers can also use it for insulating electronic parts and batteries. Your car battery will have a longer lifespan and more efficiency.
From the strength perspective, carbon fibres are the best choice. The material will have a considerable tensile strength. As electric automobile makers want to construct strong yet lightweight parts, carbon fibres are the right materials. Carbon fibre is stronger than fibreglass and is suitable for areas that need moderate-level strength. If you want a high-performance car design material, carbon fibre is the most appropriate choice. As the cost is higher, the overall manufacturing process will be costlier. So, you can choose the best brands that have used composites in electric vehicles.
Kelvar- Another composite material for electric vehicles
The lightweight yet robust material, Kelvar is basically synthetic fiber. Engineers have used it for designing EV models for impact resistance and more strength. Although some automobile makers use Kelvar, it has applications in other industries. When combined with other materials, it works as a composite material.
Which global car brands have already used composites in EVs?
Carbon fiber-reinforced plastic materials have been used for constructing BMW i8. The innovative design has minimized the weight, boosted the range, and improved efficiency. Tesla is another brand that has used carbon fibre and aluminum for the car body for better acceleration and impressive range.
Are there challenges in using composite materials for EVs?
Emissions reduction is, of course, the biggest advantage of using composites for electric vehicles. But, the most common challenge is about the vehicle value and range limits. Consumers like to consider EVs as the cost equivalent to traditional gas-powered cars. Another big challenge is the limited availability of the charging infrastructure. Only a few regions have the charging stations. Some consumers do not find an interest in EV models because of the limited access to the charging facility.
Many Western countries have successfully bridged the gap, but more improvements are essential in other countries. Moreover, the charging speed is another issue, as it is not comparable with the refuelling speed of traditional gas vehicles.
It may take time to overcome these challenges. Composite materials will help automobile engineers to make vehicles more efficient with a lightweight design. There should be more refinements for designing the converter, motor, and battery modules. Furthermore, cars with lightweight composite components and less powerful batteries should have a good range like those of stainless steel EV components.
Conclusion
Using composites in electric vehicles will bring advancements in the EV market. The energy absorption and dissipation power have made composite materials the perfect choice for designing electric vehicles. Besides, the strength and weight of the material are significant factors behind using the composites for EV models.
Composites provide safety when the EV manufacturers use them for the chassis because they uphold structural integrity. The durability of composites makes them resistant to environmental elements. More brands will use these materials for designing and engineering their cars. So, the EV market will have a bright future.
