Overview
Lightweight materials such as carbon-fibre reinforced plastics have been used up to now mostly in high-performance cars with relatively high cost & low production volumes. Instead the electric cars of the future require lightweight solutions that not only enable specific design requirements to be respected but are also cost effective and sustainable throughout their lifecycle.
ENLIGHT aims to accelerate the technological development of a portfolio of innovative thermoset, thermoplastic, bio-based and hybrid materials which together offer a strong potential to reduce weight and overall carbon footprint to enable their viable application to medium-high volume EVs in 2020-25.
Through the collaboration of EUCAR, CLEPA and EARPA, ENLIGHT will act as an open innovation platform, integrating valuable insights from other EU research projects with a holistic design approach.
Five demonstrator modules of a future EV architecture will be developed, validating the performance of the materials in structurally demanding parts of the car. The demonstration and evaluation of the lightweight potential will be supported virtually with a full vehicle model.
Funding
Results
Low-cost, high-performance electric vehicles
Reducing the environmental impact of road transport would have major benefits for the planet. Materials and processes that lead to a superior electric vehicle with minimal carbon footprint at a reasonable price should encourage widespread adoption.
To date, lightweight materials such as carbon fibre-reinforced plastics have been employed primarily in expensive high-performance cars. Developing a portfolio of lightweight materials with low carbon footprint for electric vehicles is the objective of the EU-funded project 'Enhanced lightweight design' (http://www.project-enlight.eu/ (ENLIGHT)).
The team is targeting medium-volume production of ultra-compact 4-seat passenger vehicles destined for market in the next 8-12 years. To meet their goals, scientists are working on the entire vehicle configuration, having divided up research to cover the major items contributing to overall weight. Design considers a front module, a central floor module, a front door, a sub-frame and suspension system, and an integrated cross car beam.
Highly advanced materials are under investigation, including thermoplastic matrix composites, fibre-reinforced composites, advanced hybrids and sandwich materials, and composites based on biomaterials and renewables. The team is taking a holistic view, considering performance, manufacturing, cost and life-cycle footprint. In addition, the project integrates important outcomes from other projects to increase the chances of success.
Researchers have delivered preliminary designs of the lightweight components for the five demonstrator modules. Numerous models have been developed to study noise and vibration, changes in stiffness due to electrical current and temperature changes, and micromechanical properties under loading cycles.
Materials development according to preliminary designs and simulations is proceeding for all modules. Scientists have already evaluated several manufacturing technologies. The assessment will also include an evaluation of the potential for integrating several functions into one component for less weight and space and greater simplicity in vehicle architecture.
ENLIGHT is combining simulations with experimental validation to spur the fast, efficient and reliable design and development of materials and processing solutions. Reducing the cost and environmental footprint of electric vehicles will lead to mass production and widespread market uptake. That, in turn, will significantly decrease the environmental impact of cars on the road.