Advanced Light MAterials and processes for the eco-design of electric vehicles

In the need to improve the efficiency and driving range of electric vehicles (EVs), one strategy is the weight reduction of the global vehicle.

There are already available solutions based on advanced light materials with promising structural properties but they still need further development to increase their TRL and reach the market.

Furthermore, increasing environmental awareness and forthcoming stricter regulations demands the adoption of circular economy principles across the entire vehicle life-cycle.To respond to this challenge, ALMA will develop a novel BEV structure for a passenger car with 45% weight reduction potential compared to current baseline (15% additional reduction if compared to prior-art solutions) at affordable costs (below 3€/Kg-saved of additional cost), thus enabling up to 2.2 KWh/100Km efficiency increase and 11% LCA improvement.

For this purpose, ALMA will develop a multi-material modular platform (BIW, chassis and closures) made of a combination of Advanced High Strength Steels (AHHS), Advanced-SMC and steel-hybrid materials, characterized with multiscale model-based tools.

ALMA will adopt circular economy principles from early stages through the application of eco-design strategies to create a novel BEV platform “made to be recycled”, using a structural reversible bonding technology to enable the separation of components at the end-of-life (EoL) for repair and reuse.

A ground-breaking health monitoring system based on acoustic emissions will be integrated in the structure to detect and locate damage while in-service.

At last, efficient recycling and material recovery options will be analysed to complete the circular loop.ALMA involves a well balance group of 9 partners from 4 different EU countries, 5 of them are market-oriented companies (with 2 SMEs), being one an automotive OEM. It also includes 3 RTOs and one international association.

ALMA has also gathered the support of 15 external supporting partners in the Advisory Board.