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The present paper showcases the results of the ALMA project, whose primary goal is to develop a novel electric vehicle structure for a passenger car, featuring reduced weight and environmental impact. Eco-design principles were incorporated from the early concept stages, integrating approaches like Design for Assembly and Disassembly (DFA/DFD), Design for Recycling (DFR), and functional integration of separate parts into a single structure. A FORD Mondeo with Internal Combustion Engine (ICE) was chosen as a design baseline. Subsequent redesign and material selection iterations led to the development of a novel multimaterial Battery Electric Vehicle (BEV) concept, using Advanced High-strength steel (AHSS), low-density grade steel, laminate steel/plastic, and advanced Sheet Moulding Composite (SMC). Crash modeling was performed to virtually validate the design concepts against five different crash scenarios. Ultimately, the ALMA concept car's final design can now boast a mass reduction of 160.5 kg, translating to a 22% weight reduction compared to the baseline BEV.

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Eco-Design of Lightweight Structural Components for Electric Vehicles Made of Advanced Materials

  • 会议论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年

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  • Vanessa Ventosinos Louzao,
  • Raquel Ledo Bañobre,
  • Ilya Popov,
  • Jérôme Favero,
  • Fernando Burguera,
  • Tom Ligthart

摘要

The present paper showcases the results of the ALMA project, whose primary goal is to develop a novel electric vehicle structure for a passenger car, featuring reduced weight and environmental impact. Eco-design principles were incorporated from the early concept stages, integrating approaches like Design for Assembly and Disassembly (DFA/DFD), Design for Recycling (DFR), and functional integration of separate parts into a single structure. A FORD Mondeo with Internal Combustion Engine (ICE) was chosen as a design baseline. Subsequent redesign and material selection iterations led to the development of a novel multimaterial Battery Electric Vehicle (BEV) concept, using Advanced High-strength steel (AHSS), low-density grade steel, laminate steel/plastic, and advanced Sheet Moulding Composite (SMC). Crash modeling was performed to virtually validate the design concepts against five different crash scenarios. Ultimately, the ALMA concept car's final design can now boast a mass reduction of 160.5 kg, translating to a 22% weight reduction compared to the baseline BEV.