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Purpose <p>The effectiveness of lightweighting strategies in battery electric vehicles (BEVs) depends on the environmental impacts of the electricity grid powering the vehicle during its use phase. As Europe transitions toward renewable energy sources, the environmental impacts of electricity grids are decreasing annually. This ongoing evolution creates a need for dynamically assessing the use phase impacts of automotive components to understand how evolving electricity grid mixes influence the ecodesign process.</p> Methods <p>A life cycle assessment (LCA) is performed to evaluate the environmental impacts of a prototype automobile interior door handle manufactured from a novel polymer biocomposite compared to conventional lightweight alternatives, such as carbon fiber-reinforced polymer and glass fiber-reinforced polymer. The influence of weight-induced energy consumption during the use phase in BEVs is analyzed for two electricity grid mixes, including Poland (fossil-based grid) and Portugal (renewable-based grid). Two approaches are considered for the electricity grid mixes: (i) a retrospective approach using market electricity generation datasets from the ecoinvent database (constant grid mix), and (ii) a prospective approach using dynamic forecasted market electricity generation pathways (dynamic grid mix).</p> Results and discussion <p>For ICEVs, conventional lightweight alternatives offer environmental benefits due to weight-induced energy savings and lower well-to-wheel emissions, despite having higher cradle-to-gate impacts compared to polymer biocomposites. For BEVs, material selection depends on the electricity grid mix: conventional lightweight alternatives are preferable in fossil-based grids, while polymer biocomposites are preferable in renewable-based grids, where weight-induced energy savings from lightweighting provide negligible benefits. The prospective analysis reveals that as electricity grids decarbonize, currently optimal lightweight alternatives may lose their benefits due to weight-induced energy savings, highlighting the necessity of prospective dynamic assessments in BEV component ecodesign.</p> Conclusions <p>This article highlights how the ongoing energy transition influences the effectiveness of lightweighting strategies in reducing overall life cycle impacts of automotive components. The outcomes demonstrate the critical role of the use phase in selecting optimal materials for automotive components.</p>

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How does the energy transition reshape ecodesign of automotive components in battery electric vehicles? retrospective vs. prospective life cycle assessment

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月6日

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  • Carlos Hernandez,
  • Carla Rodrigues,
  • Pedro Silva,
  • Gonçalo Tomé,
  • Clara Gonçalves,
  • Fausto Freire

摘要

Purpose

The effectiveness of lightweighting strategies in battery electric vehicles (BEVs) depends on the environmental impacts of the electricity grid powering the vehicle during its use phase. As Europe transitions toward renewable energy sources, the environmental impacts of electricity grids are decreasing annually. This ongoing evolution creates a need for dynamically assessing the use phase impacts of automotive components to understand how evolving electricity grid mixes influence the ecodesign process.

Methods

A life cycle assessment (LCA) is performed to evaluate the environmental impacts of a prototype automobile interior door handle manufactured from a novel polymer biocomposite compared to conventional lightweight alternatives, such as carbon fiber-reinforced polymer and glass fiber-reinforced polymer. The influence of weight-induced energy consumption during the use phase in BEVs is analyzed for two electricity grid mixes, including Poland (fossil-based grid) and Portugal (renewable-based grid). Two approaches are considered for the electricity grid mixes: (i) a retrospective approach using market electricity generation datasets from the ecoinvent database (constant grid mix), and (ii) a prospective approach using dynamic forecasted market electricity generation pathways (dynamic grid mix).

Results and discussion

For ICEVs, conventional lightweight alternatives offer environmental benefits due to weight-induced energy savings and lower well-to-wheel emissions, despite having higher cradle-to-gate impacts compared to polymer biocomposites. For BEVs, material selection depends on the electricity grid mix: conventional lightweight alternatives are preferable in fossil-based grids, while polymer biocomposites are preferable in renewable-based grids, where weight-induced energy savings from lightweighting provide negligible benefits. The prospective analysis reveals that as electricity grids decarbonize, currently optimal lightweight alternatives may lose their benefits due to weight-induced energy savings, highlighting the necessity of prospective dynamic assessments in BEV component ecodesign.

Conclusions

This article highlights how the ongoing energy transition influences the effectiveness of lightweighting strategies in reducing overall life cycle impacts of automotive components. The outcomes demonstrate the critical role of the use phase in selecting optimal materials for automotive components.