ULAS-E-VAN

UltraLight Body Structure of an Electric VAN

As part of the research project "ULAS-E-VAN" ("UltraLight Body Structure of an Electric VAN"), 9 partners are developing a modular battery carrier system and lightweight solutions for the body structure of battery-electric light commercial vehicles (class N1).

Modern CAE methods such as "simulation-driven design" and innovative production methods are used for this purpose. In addition to a special 3D printing process – 3D sand mold printing – to produce molds for the iron casting process, large-area, structural plastic parts are also being used.

The aim is to design a superstructure using a frame-stringer construction method and thus transfer the proven construction method used in aircraft construction to light commercial vehicle construction with higher production numbers per year. The frames are to be designed as one-piece and are bionicallyoptimized. The outer skin is formed by prefabricated plastic panels that are connected to the load-bearing structure. A load-bearing, ultra-lightweight, scalable and modular battery carrier system is to be integrated into the underbody, which functionally supports the body structure in terms of stiffness, fatigue strength and crash resistance.
The technologies used are intended to achieve weight savings of up to 150 kg at overall vehicle level, thus enabling an increased range and payload.

The research project has a total volume of 5.8 million euros and is funded by the Federal Ministry for Economic Affairs and Climate Action (BMWK).