Robotic composite filament winding technology for ultra-lightweight L7E class electric vehicles: enabling cost-effective zero emission urban mobility solutions

The pursuit of cost-effective electric vehicles (EVs) tailored for zero emission urban mobility solutions have gained significant momentum in recent years. The L7e class of EVs, specifically designed for urban transportation, presents a unique opportunity to address the challenges of polluted and congested city environments. However, the high costs of currently available EVs and lack of charging infrastructure remain significant barriers to their widespread adoption. This study explores the application of robotic composite filament winding technology with ISOGRID structure to develop an ultra-lightweight chassis for L7e class EVs, with the aim of achieving cost-effectiveness by reducing the weight, battery capacity and production costs of these advanced urban mobility solutions. Composite filament winding offers a promising manufacturing method for producing structurally efficient and lightweight components. By combining high-strength fibres, such as carbon or glass, with a polymer resin matrix, composite materials can be engineered to exhibit superior mechanical properties while significantly reducing weight. Leveraging this technology for the construction of ultra-lightweight EV chassis in the L7e class vehicles can enhance energy efficiency, extend driving range, and contribute to cost reduction. In this research which has been carried out within the frame of ZEUS (Zero Emissions Urban Mobility Solutions) R&D project led by authors, we investigate the design and manufacturing aspects of a robotic composite filament-wound ultra-light EV chassis for L7e class vehicles. Utilizing advanced computer-aided design and simulation tools, we optimize the composite layup configuration to meet stringent structural performance requirements while considering cost constraints. Extensive mechanical testing, including tensile, flexural, and impact evaluations, is performed to validate the performance and safety of the composite materials. Additionally, we examine the feasibility of integrating composite filament-wound ultra-light EV chassis into L7e class vehicles from a manufacturing standpoint. Scalability, assembly processes, and the potential for mass production are evaluated, taking into account cost-effectiveness and efficient integration within existing production lines. The environmental impact and cost analysis encompass various factors, such as raw material selection, energy consumption, and waste management, to ensure sustainability in the manufacturing process.