Light-eBody

Research consortium develops lightweight body for electric vehicles

The resource-saving and energy-efficient design of an entire vehicle is of great importance, especially when it comes to vehicles with electric propulsion. Thus, a special lightweight body for electric vehicles should was developed within the scope of the national publicly funded project LIGHT-eBODY, led by Volkswagen Group Research.

Besides aerodynamics and the further development of battery technology lightweight constructions are especially appropriate to reduce energy consumption and therefore extend the range. Thus, a research consortium of 14 partners developed a light, resource-saving multi-material body for electric vehicles suitable for large scale production within three years.

Prof. Dr. Jürgen Leohold, director of Volkswagen Group Research, which coordinated the project, explains: „The body weight is of great importance, especially when it comes to range optimisation of electric vehicles. At the same time it is necessary that new body concepts with multi-material constructions do not only meet the usual safety and quality standards of automotive industry, but also have some special features regarding electro mobility. Specific requirements are for example the safe and weightoptimised integration of the battery into the vehicle architecture.“

The reduction of weightof 68 kg became possible with the help of an optimal use of different materials in a concept that is consequently tailored to the requirements of an electrically powered vehicle. A battery pack that is integrated into the structure contributes to stability and safety of the vehicle and therefore provides access to further lightweight potential. In addition to the design of new material concepts and manufacturing processes for multi-material lightweight bodies, the focus was on the development of necessary simulation technologies and appropriate joining methods as those were only existing partially for the expected combinations of material.

LIGHT-eBODY was a joint project of the automobile manufacturers Ford and Volkswagen, other industrial partners and research institutes from Germany. The project partners in particular are: Ford Advanced Research & Development Aachen, Volkswagen Group Research, the Institutes for Automotive Engineering, Welding and Joining as well as Laboratory for Machine Tools and Production Engineering of RWTH Aachen University, Altair Engineering GmbH, Dow Automotive Systems, Fraunhofer LBF, Hydro Aluminium, Laboratory for Joining and Material of University of Paderborn, Linde + Wiemann GmbH KG, Röchling Automotive AG & Co. KG, ThyssenKrupp Steel Europe AG and Wilhelm Böllhoff GmbH & Co. KG.