Application of Composites in the Development of Electric Vehicles

China was one of the early adopters of electric buses, but with a sharper public and legislative focus on air quality in highly populated areas and global emission levels, the adoption trend is growing worldwide. Such electric vehicles (EVs) are now offering a solution for running public transport without the adverse effect of polluted exhaust gases on the environment. Instigated by global carbon emission reduction targets, this technology is rapidly increasing its footprint to other EVs such as electric cars, cargo bikes, scooters, and even aircraft. With advancements in battery technology and the application of composites, we see a great potential and bright future for electric vehicles. 

The challenges of electric vehicle adoption 

Moving towards a new generation of power trains comes with certain challenges for the manufacturers. First, there’s the question of weight. EVs must be light to operate with enough efficiency on the move. When taking passengers into account, as well as a limited range between charging stations, minimizing the weight of every single component is of the utmost importance. 

Secondly, unlike diesel or petrol buses, EVs carry a large amount of electric current, which requires them to be adequately insulated. It needs to be ensured that conduction to other parts of the power train and reverse polarization cannot occur. 

The final challenge is building a sufficient knowledge base to be able to originate a completely new electrified platform. As the transportation industry is experiencing a huge shift towards electrification, many organizations across the globe don’t have access to the engineering expertise required for developing fit for purpose bus components. 

In composites lies the answer

By utilizing the benefits of composite materials it becomes possible to design and construct complex and robust, yet lightweight assemblies. They have become a staple of racing vehicles worldwide, but when we’re talking about civil vehicles, it translates both to increased performance and range. Suppliers of composite materials have spent decades developing lightweight carbon fiber components for automobiles, trucks, aircraft, and water transport – all to improve cost and fuel efficiency. 

The challenge is to find the optimum cost-performance ratio, when using composite materials. 

The possibilities of mass transit were the next logical step because governments and manufacturers today recognize how these materials can reduce road wear and fuel consumption. When it comes to buses, the benefits of reduced weight and fuel consumption is reportedly higher than with other types of road vehicles. Manufacturers are able to remove about 2,000 kilos of weight compared to metal bus chassis and frames, which allows them to store more energy and increase the driving range. 

Composites can also replace aluminium, are less prone to corrosion, and comply with flame resistance requirements. In EV production processes, manufacturers nowadays are embracing various composite design techniques and production techniques, ranging from monocoque, load carrying structure composed of prepreg composite material, to low-cost pultruded composite materials for secondary structure applications. Steel bus frames have a 12-year life-span and experience corrosion over time. A composite bus body is corrosion- and impact-resistant, prolonging its lifespan significantly. The challenge is to find the optimum cost-performance ratio, when using composite materials. 

Composite bus body is a green transit solution 

Besides the benefits in performance, the transition to composite EVs will have a significant economic and environmental impact. We all know that diesel and petrol vehicles are increasingly more costly to operate and own, and they pollute our environment. By utilizing composite EV technology, we can drive down costs and replace fossil fuel transit vehicles with fully electric ones. 

Since 2007, Pontis Engineering has grown to become one of the leading companies in the industry of composite products. With offices in the Netherlands (headquarters), the U.S., and China. We have a dedicated team of highly experienced engineers who develop advanced composite products for our customers, making them more competitive.