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<p>The transition from internal combustion engine (ICE) vehicles to electric vehicles (EVs) has significantly redefined automotive structural engineering and manufacturing paradigms. A major enabler of this transformation is sheet-metal engineering, which governs the design, forming, joining, and integration of thin-walled metallic components into lightweight yet crashworthy EV architectures. The presence of heavy battery systems demands aggressive lightweighting strategies while ensuring structural stiffness, impact resistance, and thermal safety. Advanced aluminum alloys and advanced high-strength steels (AHSS) are increasingly adopted to achieve superior strength-to-weight ratios. However, these materials introduce challenges such as limited formability, spring-back, and tooling complexity. This paper presents a detailed survey of sheet-metal engineering technologies for EV structures, incorporating material modeling, advanced forming algorithms, mechanical equations, process optimization strategies, and sustainability considerations. Comparative tables, algorithmic frameworks, and mathematical formulations are provided to establish a structured understanding of EV sheet-metal system design.</p>

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Sheet-Metal Engineering for Electric Vehicles: Enabling Lightweight, Safe, and Efficient EV Structures

  • 期刊论文

  • 发表日期：

    2026年5月24日

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  • K. Shiva Kesava Reddy,
  • M. Ramakanth Reddy,
  • V. Shiva Narayana Reddy,
  • Aseenababu Shaik,
  • M. Rejeswara Reddy,
  • Perumalla Janaki Ramulu

摘要

The transition from internal combustion engine (ICE) vehicles to electric vehicles (EVs) has significantly redefined automotive structural engineering and manufacturing paradigms. A major enabler of this transformation is sheet-metal engineering, which governs the design, forming, joining, and integration of thin-walled metallic components into lightweight yet crashworthy EV architectures. The presence of heavy battery systems demands aggressive lightweighting strategies while ensuring structural stiffness, impact resistance, and thermal safety. Advanced aluminum alloys and advanced high-strength steels (AHSS) are increasingly adopted to achieve superior strength-to-weight ratios. However, these materials introduce challenges such as limited formability, spring-back, and tooling complexity. This paper presents a detailed survey of sheet-metal engineering technologies for EV structures, incorporating material modeling, advanced forming algorithms, mechanical equations, process optimization strategies, and sustainability considerations. Comparative tables, algorithmic frameworks, and mathematical formulations are provided to establish a structured understanding of EV sheet-metal system design.