Top-Down Design Approach of Lightweight Composite Battery Pack Enclosure for Electric Vehicles Based on Numerical
Xin Zhang1,2, Qiang Lin1,2, Ying Xiao1,2
1Fujian Provincial Key Laboratory of Terahertz Functional Devices and Intelligent Sensing, School of Mechanical Engineering and Automation, Fuzhou University, Fuzhou 350108, China.
Polymers
|November 13, 2025
Summary
This study developed a lightweight carbon fiber reinforced plastic (CFRP) battery enclosure for electric vehicles (EVs) using topology optimization. The efficient design balances performance, cost, and production for mass manufacturing.
Area of Science:
- Materials Science
- Automotive Engineering
- Structural Optimization
Background:
- Electric vehicles (EVs) require lightweight structural components for improved performance and safety.
- Battery-pack enclosures are critical for EV driving range, safety, and handling.
- Carbon Fiber Reinforced Plastic (CFRP) is increasingly used for structural lightweighting in automotive applications.
Purpose of the Study:
- To design and fabricate a lightweight CFRP battery-pack enclosure for EVs.
- To optimize the enclosure design using a top-down approach and topology optimization.
- To achieve cost-effective mass production while meeting performance targets.
Main Methods:
- A top-down design strategy was employed.
- Topology optimization was utilized for structural and geometric parameter refinement.
- The composite enclosure was fabricated using the compression molding process.
Main Results:
- Maximum deformations of 0.56 mm (in-plane) and 10.33 mm (lateral) were recorded.
- The final prototype weighed 4.78 kg.
- A rapid curing cycle of 10-15 minutes was achieved.
Conclusions:
- A lightweight CFRP battery-pack enclosure with cross-shaped stiffeners was successfully manufactured.
- The integrated design approach balances lightweighting, cost-effectiveness, and production efficiency for EVs.
- This study presents an effective method for optimizing EV battery enclosure design.
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