Demonstrating the Lessons Learned for Lightweighting EV Components through a Circular-Economy Approach

Abstract

LEVIS is an innovation project funded by the EU Horizon 2020 program. Its main objective is to develop lightweight multi-material solutions based on bio-based materials and carbon fiber thermoplastic composites for electric vehicle components and demonstrating the technical, operational, and economic feasibility of applying eco-design and circular-economy principles into the design process. The project demonstrates the application of these materials in four case studies: a suspension control arm, a battery box, a battery module housing, and a cross-car beam. All demonstrators achieved a 20%-to-40% reduction in component weight, but environmental assessment results varied significantly, with emissions changes ranging from an increase for suspension control arms to a 65.5% decrease for battery modules. Efficient use of materials, particularly in the battery box using hybrid solutions and bonding technologies, showed notable emissions reduction. In contrast, replacing steel with CFRPs in suspension control arms led to increased emissions, suggesting that CFRPs are more effective for replacing high-polluting materials like aluminum. Recycled carbon fibers proved more beneficial for low-polluting materials like steel. The environmental performance of technologies depends on the expected use of EVs and the electricity grid mix, with better outcomes in coal-reliant grids. Finally, no single recycling method is universally superior; the optimal method depends on the specific technologies and the energy required for recycled materials.