Lightweight Composites for E-Mobility Applications

Abstract

The transition to electric mobility necessitates a re-evaluation of materials to enhance energy efficiency, improve driving ranges, and enhance durability. Lightweight composites have emerged as crucial materials for electric vehicles (EVs) owing to their high strength-to-weight ratio, corrosion resistance, and versatile design possibilities. This article reviews the history, processing techniques, and performance evaluation of lightweight composites used in various e-mobility components, including as frames, battery enclosures, interior panels, and structural elements. The paper discusses conventional and advanced fiber reinforcements (e.g., carbon, glass, and natural fibers), matrix systems (thermosets, thermoplastics, hybrid polymers), and fabrication methods including resin transfer molding (RTM), filament winding, additive manufacturing, and compression molding. Emphasis is laid on the integration of multifunctional features such as thermal stability, electromagnetic shielding, and recyclability in composite systems. The challenges of delamination, cost-efficiency, joining with metals, and fire resistance are reviewed. Current trends such as bio-based composites, nano-enhanced fillers, and AI-enabled material optimization for automotive design are also presented. This review aims to bridge material selection, processing innovation, and design engineering, ultimately contributing to the realization of next-generation electric vehicles that are not only lightweight but also high-performing and sustainable. Recommendations for future research are provided in light of industry standards and life-cycle analysis considerations.