Research Projects - Lightweight Design and Body Structures

Ultra Light Body Structure of an Electric VAN

The research project "ULAS-E-VAN" ("Ultra light body structure of an electric VAN") involves 9 partners developing lightweight solutions for the body structure and a modular battery tray system of battery-electric light commercial vehicles (class N1). For this purpose, modern CAE methods, such as "Simulation-Driven-Design" and innovative manufacturing methods, are used. In addition to a special 3D printing process – 3D sand mold printing – for the production of dies for the iron casting process, large-area structural plastic parts are also used.

The structural design is based on a frame-stringer construction, thus transferring the construction method proven in aircraft construction to light commercial vehicle construction with higher production volumes per year. The frames should be designed as one-piece and bionically optimized wherever possible. The outer skin will be formed by pre-formed plastic panels that are joined to the structure in a load-bearing design. The underbody will integrate a load-bearing, ultra-lightweight, scalable and modular battery tray system, which will functionally support the body structure in terms of stiffness, fatigue strength and crash.

The applied technologies are expected to achieve weight savings in the range of up to 150 kg on the overall vehicle level, thus enabling an increased range or payload.

The research project has a total volume of 5.8 million euros and is funded by the German Federal Ministry of Economics and Climate Protection (BMWK).