Lightweight construction: First composite gearbox housing with layer-optimized organo sheeting weighs 30% less than a comparable aluminum component

Abstract

When it comes to electric vehicles, keeping weight down is paramount in ensuring long range. In addition to the bodywork, drive components such as the housings typically used in double reduction gearboxes are of interest in terms of materials’ substitution. Thanks to their mechanical properties and the well-established production possibilities, carbon fiber-reinforced thermoplastics have plenty to offer. The challenge, however, is maintaining the required rigidity levels at prevailing operating temperatures. Together with its sister companies, ARRK Engineering has taken up this highly promising challenge: in 2016, a fully functional thermoplastic composite gearbox housing for electric vehicles was developed as part of a self-financed development project, with the first half already implemented as a prototype.