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Ultra-lightweight solutions for E-Van
Friedberg, Germany, December 8, 2022 Reducing weight to increase range: With this goal, nine partners from research and the industry are working on the ultra-light body structure of an electric van. As part of the consortium, voxeljet AG (NASDAQ: VJET) is supplying sand casting molds and cores for large-format structural body parts. With the VX4000, the world’s largest 3D printing system for sand molds, voxeljet can produce parts with highly complex, weight-saving geometries and a size of more than two meters in one piece. Compared to conventional die casting, where many individual parts have to be cast and assembled, sand casting is much more cost-effective and faster for product development, as there is no need for costly toolmaking.
As part of the research project “ULAS-E-VAN” (“UltraLeicht AufbauStruktur eines Elektrischen VANs” – UltraLightweight Body Structure of an Electric VAN), nine partners are developing lightweight solutions for the body structure and a modular battery carrier system of battery-electric powered light commercial vehicles ( commercial vehicles, class N1 – Ford Transit – BEV). Ford is coordinating the research project with a total volume of 5.8 million euros, funded by the German Federal Ministry of Economics and Climate Protection (BMWK). The project partners are Altair Engineering GmbH, BENTLER Automobiltechnik GmbH, C-TEC GmbH, Ford-Werke GmbH, Franken Guss GmbH + Co. KG, MORPHOTEC, RWTH Aachen University, Chair and Institute for Structural Mechanics and Lightweight Construction (SLA), RWTH Aachen University, Institute for Automotive Engineering (ika), and voxeljet AG.
If a light commercial vehicle is equipped with an electric drive, the empty weight increases due to the high battery weight and the possible payload decreases. To counteract this, it is imperative to decisively reduce the weight, especially in battery-powered delivery vehicles, through lightweight construction measures. Lightweight construction makes it possible to increase the range, but also to reduce the battery size, secondary weight and thus battery costs while keeping the range unchanged. However, in the targeted sector of e-commercial vehicles, the need for cost-effective lightweight construction is even more critical due to the high-cost sensitivity of the potential customer base and the relatively low unit numbers.
This is where the project comes in. The consortium aims to develop ultra-lightweight solutions for the body and superstructure of such battery-electric light commercial vehicles using modern CAE methods such as “simulation-driven design” and innovative manufacturing methods. In addition to a special 3D printing process – 3D sand mold printing – to produce molds for the iron casting process, large-format structural plastic parts are also used.
The design of the body structure is to be based on a frame-stringer construction, thus transferring the proven aircraft construction method to light commercial vehicle construction with higher annual production figures. The frames are to be designed as a single piece wherever possible and in a bionic-optimized manner. The outer skin will be formed by prefabricated plastic panels that are connected to the load-bearing structure. A load-bearing, ultra-lightweight, scalable and modular battery support system is to be integrated in the underbody, which will provide functional support for the body structure in terms of stiffness, fatigue strength and crash. The technologies used are expected to achieve weight savings in the order of up to 150 kg on a total vehicle level, thus enabling an increased range or payload.
US foundry invests in second VX4000
voxeljet AG, a leading global technology provider of industrial 3D printing solutions, has sold another VX4000 system, one of its largest 3D printers, to Tooling & Equipment International (TEI).
