International Energy Agency (IEA) states that electric vehicle sales increased 25% year-over-year as over 3 million electric cars were sold in the first quarter of 2024 compared to the same period in 2023. According to a joint report by the Automotive Component Manufacturers Association (ACMA) and Grant Thornton Bharat, the Indian Electric Vehicle (EV) market is set to grow significantly, with an expected value of Rs 318,000 crore by 2030. EV manufacturing has the immersive growth among the industries as technology grows. Aluminum and magnesium lightweight materials reduce the overall weight of the vehicle which reduces energy consumption of the vehicle that impacts the greenhouse gas emissions. Automakers estimate that every 10% drop in vehicle weight can translate into a 6-8% rise in fuel economy. Lightweight materials are strong enough in using EV manufacturing and these materials are less expensive than traditional materials like steel. Electric vehicles are high-performance with quiet and smooth motors and require less maintenance than internal combustion engines, such as an oil change.
Lightweight materials improve energy efficiency, vehicle handling, longer driving range, and braking performance in electric vehicles. Lighter parts have lower material costs than heavier parts, which reduces the cost of materials and leads to growth in EV manufacturing. In addition, the lightweight casting materials reduce the vehicle’s weight, and enable more efficient energy usage, as the battery and motor require less effort to propel the vehicle which reduces the energy consumption and longer driving distances per charge. Regenerative braking systems can be more effective by using lightweight materials to reduce vehicle mass while maintaining strength, durability, and safety. Further energy conservation can be achieved during braking which extends the range of the battery as well as fuel efficiency. The use of aluminum and magnesium alloys offers corrosion protection which will increase the life of the EV's components even when used under extreme environmental conditions.
Harunar Rashid, Founder & Chief Product Designer, Enception EV Inc says "Where consistency and scalability are essential, the potential of forged carbon fiber doesn’t always translate well to mass production. In comparison, materials like cast aluminum, though not as lightweight or strong, offer a more feasible solution due to their accessibility, ease of production, and reliability in large quantities. Balancing innovation with practicality remains key in the evolving landscape of EV manufacturing".
As the world transitions towards renewable energy sources, lightweight materials in EV manufacturing make an object lighter, without compromising its strength or performance which reduces the amount of material used in the manufacturing. Less stress among the batteries and less fuel consumption leads to less carbon emission in the environment. Mining, processing raw materials, and resource extraction often have significant environmental impacts. Lightweight materials reduce the amount of raw materials required per vehicle and the overall demand for these resources. Moreover, aluminum, magnesium, and lithium materials are recyclable and can be recycled often at the end of the vehicle’s life. According to Techvanio, the battery recycling market size is expected to grow by US $11.34 billion from 2024-2028. Using lithium-ion batteries in EV manufacturing leads to electric vehicle battery recycling. The purified metals are recovered and can be reused in new products. Recycling leads to a reduction in the amount of waste that goes into landfills which helps to conserve natural resources reduce pollution and save energy.
Casting techniques such as die casting, investment casting, and sand casting enable the creation of complex, lightweight components for various parts including batteries, motor housings, and structural components that lead to the mass production of aluminum components. Aluminum components are lighter than steel but still have the durability for electric vehicle applications because of sufficient strength. However Magnesium is lighter than aluminum but when casting, it can be used in high-performance parts such as EV frames and battery cases to significantly reduce weight. In advance, investment casting and shell molding are used to create parts that are both lightweight and strong enough to handle the electric vehicle performance, especially in high-stress areas like motors and suspension systems. Additionally, 3D printing holds a vital role in EV manufacturing by mass producing small and critical parts which leads to speed up the production and the production of multi-materials and multi-process batteries for electric vehicles. Engineers can develop low-cost electric vehicle batteries by reducing material costs by up to 50% using 3D printers.
Rakesh Mishra, CEO & Co-Founder, Entuple E-Mobility says, “By modernizing casting capabilities and adopting advanced manufacturing technologies, the country can not only meet the demand for lightweight materials but also establish itself as a global leader in the production of high-performance EV components, driving sustainable growth in the sector”.
According to Gartner Forecast, 85 Million Electric Vehicles will be on the road by the end of 2025. Electric Vehicles in use will grow 33% in 2025. 73% of Electric Vehicles will be battery Electric Vehicles in 2025. By 2030, Automakers will enable the recycling of 95% of batteries from Electric Vehicles. In India, the report predicts that 500,000 EVs will be on the road by the end of 2025, including 370,000 Battery Electric Vehicle (BEV) and 129,500 Plug-in hybrid electric vehicles (PHEV) which represents 51% growth in the Indian EV market. Aluminum and magnesium provide a high-quality crash performance. Manufacturers might use a combination of aluminum, magnesium, and advanced composites in different parts of the vehicle to optimize weight without sacrificing strength, balance performance, cost, and safety. The advancements in material design will ensure that lightweight parts still meet crash safety standards. Electric motors become more efficient and compact, and lightweight castings for motor housings, gears, and other powertrain components will continue to evolve which will improve performance and overall energy efficiency. As charging infrastructure expands and technology advances, electric vehicles are captivated by more consumers which make EVs a more sustainable and environmentally friendly transportation option in the long term.
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