The LEVIS H2020-LC-GV-2020 project, coordinated by ITAINNOVA, aims to develop lightweight components for electric vehicles through the use of new multi-material technologies and is conceived within the framework of the circular economy.
The technical and economic feasibility, as well as its environmental impact, will be demonstrated through three real applications: a suspension control arm, the battery clamping system and a cross beam.
LEVIS aims to develop solutions for these multi-material components based on environmentally friendly resins and reinforcement systems, cost-effective manufacturing processes, optimized joining, advanced simulation methodologies and structural integrity monitoring technologies. The combination of these developments will make it possible to obtain lightweight, cost-effective and environmentally friendly components, without compromising their mechanical performance, structural integrity and reliability, even improving their service life.
LEVIS makes use of multi-material solutions based on metal-integrated fiber-reinforced thermoplastic composites, which will be produced using cost-effective and scalable manufacturing technologies. The technical and economic feasibility of producing these components will be demonstrated on three large-scale real case demonstrators: a suspension arm, a battery box assembly and an automotive cross beam.
After one year of the LEVIS project, the formulation of thermoplastic composite resins with good adhesion to metals for optimized one-shot manufacturing is well advanced. Both the cellulose bio-based carbon fibers and the innovative thermoplastic acrylic tapes have been manufactured on a pilot scale.
The fabrication of component sensors with sensing and condition monitoring capabilities to track the in-service mechanical performance of target parts was successfully completed. In addition, the combination of materials and processes for each of the LEVIS demonstrators has been defined and the methodology for the optimization of dissimilar joints has been defined.
After twelve months of LEVIS, we are on the right track of developing the technology pillars (novel materials, cost-effective processes, structural health monitoring (SHM) and end-of-life solutions) that will enable industries to design and produce the lightweight, cost-effective and sustainable components of the electric vehicles of the future.
In turn, a life cycle assessment (LCA) methodology is being developed to ensure that lightweight materials, manufacturing technologies and recycling processes result in improved environmental performance. After evaluating the reference configuration, a second LCA will be performed for the LEVIS demonstrators once the detailed designs and processes are fully defined.
“LEVIS aims to achieve a global warming potential reduced by 7% at the vehicle level and 25% at the component level compared to the reference scenario,” explains Esther van Bergen, managing director of Cenex Nederland and leader of the iEDGE (eco-design) toolbox development.
