Advancements in technology has played a pivotal role in driving this transformation, particularly in the development of electric and hybrid vehicles, which necessitate different manufacturing processes than those used for traditional gasoline-powered vehicles. As the demand for electric vehicles continues to surge, automotive manufacturers are compelled to adapt their production processes to meet this evolving market. One of the most significant changes is the shift towards lightweight materials. With the transition from internal combustion engines to electric motors, novel design and manufacturing considerations are required to ensure the success of these new vehicles.

Why is lightweighting so important for electric vehicles?

Electric vehicle lightweighting is important for several reasons. Firstly, reducing the weight of an electric vehicle helps to extend its range. Electric vehicles rely on batteries for power, and the lighter the vehicle, the less energy is required to move it. This means that a lighter vehicle can travel further on a single charge, making it more practical for everyday use.

Light weighting also helps to improve the efficiency of an electric vehicle. This is because a lighter vehicle requires less energy to accelerate and maintain speed, which in turn means that less energy is required from the battery. This improved efficiency can result in cost savings for the owner, as well as reducing the vehicle's environmental impact.

How are EV manufacturer's lightweighting?

Manufacturers of electric vehicles are employing a combination of methods to ensure their vehicles are as light as possible in order to improve the performance, efficiency, and environmental sustainability of their vehicles. This includes optimising design by redesigning vehicle structures, using advanced manufacturing techniques such as 3D printing as well as integrating systems such as the power electronics and electric motor which reduce the number of components required.

However, one of the most obvious methods involves manufacturers opting for the use of lightweight materials such as aluminum, carbon fiber, and composites over the likes of traditional materials such as steel.

Aluminium is commonly used in the automotive industry due to its strength, durability, and corrosion resistance. It is also recyclable, which makes it an environmentally friendly choice. Aluminium is used for vehicle bodies, frames, and other components, helping to reduce weight and improve efficiency.

Carbon fibre is a high-strength and lightweight material that has been used extensively for years in the aerospace industry. It is made from carbon fibers that are woven together and then coated with resin. Carbon fibre is becoming more commonly used in electric vehicle manufacturing to reduce weight while maintaining structural integrity, improving the vehicle's range and performance.

Composites are materials made from a combination of multiple materials, such as fiberglass or carbon fibre reinforced polymers. They are lightweight, durable, and can be moulded into complex shapes, making them an ideal choice for electric vehicle components such as body panels, suspension components, and battery enclosures.

How does GESIPA support EV lightweighting?

At GESIPA^®, we take great pride in our extensive portfolio of blind rivets and blind rivet nuts, which have been designed and developed specifically to meet the rigorous demands of the automotive industry and its various applications. We have recently expanded our range to include products that are tailored towards the manufacturing of electric vehicles and battery boxes, further demonstrating our commitment to innovation and meeting the evolving needs of the industry.

Battery boxes - GESIPA^® engineering boasts extensive expertise in the production of a variety of precision-engineered components such as pressed, fabricated, extruded, and formed parts. Drawing upon our years of industry experience, we are well-positioned to offer valuable insight and support in the development of the next generation of battery boxes. Our team is equipped to address the unique challenges associated with the design and manufacture of these critical components, including achieving optimal weight reduction, maximizing available space, and preventing water ingress.

GESIPA^® LightWeight (SpaceSaver) - Through tireless research and development efforts, we have successfully created a product that utilises 50% less material than traditional rivet nuts, while maintaining the same level of technical performance. This groundbreaking achievement not only represents a significant cost-saving opportunity for our customers, but also offers numerous benefits in terms of assembly and application. By reducing the size and weight of our rivet nuts, we have enabled their use in a wider range of settings, even in instances where conventional rivet nuts would not fit. With GESIPA® LightWeight rivet nuts, we continue to push the boundaries of what is possible in the realm of precision engineering, and we remain committed to delivering cutting-edge solutions to our customers.

GESIPA^® SoftGrip - GESIPA's commitment to innovation is further exemplified by our SoftGrip range, specially engineered to address the unique challenges posed by lightweight materials such as plastics and carbon fibre. These specialised rivet nuts utilise crimped areas that are designed to provide a secure and dependable fastening solution, without the risk of breakage, delamination, or cracking of the application material. By incorporating GESIPA® SoftGrip rivet nuts into their production processes, electric vehicle manufacturers have benefitted from enhanced efficiency, reduced risk of damage, and increased reliability.

GESIPA^® G-Sealed^® - GESIPA^® understands the importance of protecting sensitive components such as batteries and interiors from the potentially harmful effects of water ingress, and is proud to offer our G-Sealed^® range. Designed to provide a secure and reliable water seal effectively safeguarding against the damaging effects of water infiltration, our G-Sealed^® blind rivet nut is equipped with a non-reactive pre-coating, to create a seal under the head of the blind rivet nut. Sealing is possible directly after installation. It also provides excellent thermal and chemical resistance, but is not subject to labelling requirements, therefore is not hazardous or environmentally harmful. With G-Sealed® rivet nuts, electric vehicle manufacturers can benefit from enhanced protection and peace of mind, knowing that their critical components are shielded from the hazards of water damage.

Owing to our high standards and innovations, we have come to be seen as a reliable development partner within the automotive sector over the years and we always meet the quality requirements of our customers.

For more information on how GESIPA^® can support you, please get in touch with one of our experts now!

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