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Top-Down Design Approach of Lightweight Composite Battery Pack Enclosure for Electric Vehicles Based on Numerical Modeling and Topology Optimization.

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Title: Top-Down Design Approach of Lightweight Composite Battery Pack Enclosure for Electric Vehicles Based on Numerical Modeling and Topology Optimization.
Authors: Zhang, Xin1,2 (AUTHOR), Lin, Qiang1,2 (AUTHOR), Xiao, Ying1,2,3 (AUTHOR), Jia, Liyong3,4 (AUTHOR), Yang, Tiantian4,5 (AUTHOR), Wang, Lei5,6 (AUTHOR), Ma, Quanjin1,6 (AUTHOR), Wang, Bing1,2 (AUTHOR)
Source: Polymers (20734360). Nov2025, Vol. 17 Issue 21, p2897. 21p.
Subjects: Electric vehicles, Composite structures, Structural optimization, Industrial costs, Design techniques, Computer simulation, Fiber-reinforced plastics
Abstract: To meet the increasing demands for structural lightweighting in electric vehicles (EVs), carbon fiber reinforced plastic (CFRP) has been gradually introduced to reduce weight and enhance passenger safety in automotive engineering. The battery-pack enclosure is a key structural component for EVs, as it significantly influences the driving distance, safety, and road handling of EVs. This study presents a top-down design approach and topology optimization for a lightweight CFRP battery pack enclosure reinforced with cross-shaped stiffeners. The main objective is to develop an efficient composite enclosure that meets performance targets while accommodating the demands of cost-effective mass production. The composite battery pack enclosure was fabricated using the compression molding process. Topology optimization was carried out in the preliminary design stage on the structural shape and geometric parameters following a top-down design approach. Experimental tests recorded maximum deformations of 0.56 mm and 10.33 mm under in-plane and lateral loads, respectively. The final prototype product achieved a total mass of 4.78 kg with a rapid curing cycle of 10–15 min. In conclusion, a lightweight composite battery-pack enclosure with cross-shaped stiffeners was successfully manufactured, integrating a top-down design approach with topology optimization. This study demonstrates an effective design approach to achieving an optimal balance of lightweight, cost-effectiveness, and production efficiency for EV battery-pack enclosures. [ABSTRACT FROM AUTHOR]
Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Top-Down Design Approach of Lightweight Composite Battery Pack Enclosure for Electric Vehicles Based on Numerical Modeling and Topology Optimization.
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  Data: <searchLink fieldCode="AR" term="%22Zhang%2C+Xin%22">Zhang, Xin</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lin%2C+Qiang%22">Lin, Qiang</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Xiao%2C+Ying%22">Xiao, Ying</searchLink><relatesTo>1,2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Jia%2C+Liyong%22">Jia, Liyong</searchLink><relatesTo>3,4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yang%2C+Tiantian%22">Yang, Tiantian</searchLink><relatesTo>4,5</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Lei%22">Wang, Lei</searchLink><relatesTo>5,6</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ma%2C+Quanjin%22">Ma, Quanjin</searchLink><relatesTo>1,6</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Bing%22">Wang, Bing</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Polymers+%2820734360%29%22">Polymers (20734360)</searchLink>. Nov2025, Vol. 17 Issue 21, p2897. 21p.
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  Data: <searchLink fieldCode="DE" term="%22Electric+vehicles%22">Electric vehicles</searchLink><br /><searchLink fieldCode="DE" term="%22Composite+structures%22">Composite structures</searchLink><br /><searchLink fieldCode="DE" term="%22Structural+optimization%22">Structural optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Industrial+costs%22">Industrial costs</searchLink><br /><searchLink fieldCode="DE" term="%22Design+techniques%22">Design techniques</searchLink><br /><searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Fiber-reinforced+plastics%22">Fiber-reinforced plastics</searchLink>
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  Label: Abstract
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  Data: To meet the increasing demands for structural lightweighting in electric vehicles (EVs), carbon fiber reinforced plastic (CFRP) has been gradually introduced to reduce weight and enhance passenger safety in automotive engineering. The battery-pack enclosure is a key structural component for EVs, as it significantly influences the driving distance, safety, and road handling of EVs. This study presents a top-down design approach and topology optimization for a lightweight CFRP battery pack enclosure reinforced with cross-shaped stiffeners. The main objective is to develop an efficient composite enclosure that meets performance targets while accommodating the demands of cost-effective mass production. The composite battery pack enclosure was fabricated using the compression molding process. Topology optimization was carried out in the preliminary design stage on the structural shape and geometric parameters following a top-down design approach. Experimental tests recorded maximum deformations of 0.56 mm and 10.33 mm under in-plane and lateral loads, respectively. The final prototype product achieved a total mass of 4.78 kg with a rapid curing cycle of 10–15 min. In conclusion, a lightweight composite battery-pack enclosure with cross-shaped stiffeners was successfully manufactured, integrating a top-down design approach with topology optimization. This study demonstrates an effective design approach to achieving an optimal balance of lightweight, cost-effectiveness, and production efficiency for EV battery-pack enclosures. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/polym17212897
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        Text: English
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        PageCount: 21
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        Type: general
      – SubjectFull: Composite structures
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      – SubjectFull: Structural optimization
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      – SubjectFull: Industrial costs
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      – SubjectFull: Design techniques
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            – D: 01
              M: 11
              Text: Nov2025
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              Y: 2025
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