Design and Optimization of a Lightweight Hybrid Electric Vehicle Chassis Using Topology Optimization and Advanced Composites

Project Abstract

The rapid advancement of electric vehicle (EV) technology demands chassis solutions that deliver superior strength-to-weight ratios, crash safety, and manufacturability while minimizing total vehicle mass to maximize efficiency and range. This study presents a comprehensive design and optimization workflow for a lightweight hybrid electric vehicle chassis, integrating topology optimization with advanced composite materials to achieve high stiffness, energy absorption, and damage tolerance under realistic load cases. The research adopts a multi-disciplinary approach, combining structural optimization, materials science, crashworthiness analysis, and manufacturing feasibility to produce a viable chassis solution suitable for mass production. A finite element (FE) model of a representative mid-size EV chassis is developed, capturing critical load paths, multi-axial loading scenarios, and dynamic *in-service* conditions including steering, braking, cornering, and collision events. Topology optimization is employed to identify material layout that minimizes structural compliance and weight while satisfying stringent safety and performance constraints. The optimization integrates surrogate modeling and multi-objective criteria to balance stiffness, strength, energy absorption, and crashworthiness metrics. A progressive material selection strategy explores hybridization of high-strength steels, aluminum alloys, and carbon/aramid reinforced polymers, with a focus on laminated and sandwich composite configurations to exploit face sheet stiffness and core energy dissipation mechanisms. The study advances to concept-level to detailed-level design iterations, where composite layups, joint detailing, and manufacturability constraints are embedded within the optimization loop. A damage-tolerant framework assesses delamination resistance, impact damage propagation, and residual stiffness post-crash, ensuring compliance with relevant automotive safety standards. The replacement of traditional metal closures and reinforcements with energy-absorbing composite subassemblies is evaluated for weight savings, cost implications, and repairability. A robust verification plan includes linear and nonlinear FE simulations, including explicit dynamics for crash scenarios and progressive failure analysis to predict failure modes and safety margins. Key outcomes include (i) a topology-optimized chassis topology with reduced mass by a target percentage while maintaining or enhancing specific stiffness and crash performance; (ii) optimized composite laminate configurations and hybrid material stacking sequences that maximize energy absorption and structural integrity under impact; (iii) a validated FE framework capable of predicting dynamic response, deformation, and failure with acceptable correlation to experimental benchmarks; (iv) a lifecycle and manufacturability assessment detailing production feasibility, repair strategies, and cost implications for scale-up. Sensitivity analyses identify critical parameters driving performance, such as ply orientation, adhesive interfaces, and joint stiffness. The work contributes to the field by delivering a systematic, data-driven methodology for designing lightweight, crash-safe EV chassis using topology optimization and advanced composites, offering a blueprint for bridging conceptual design and practical implementation in future electric mobility platforms.

Project Overview

What This Project Is About

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A plain-language overview of the topic and what the project investigates.

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The Problem It Addresses

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What problem or gap this project tackles and why it matters to the field or society.

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Objectives of the Project

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1. Understand how a vehicle chassis carries loads and how weight affects performance.
2. Explore topology optimization to find lighter designs that still meet safety and stiffness needs.
3. Evaluate the use of advanced composite materials to replace traditional metals.
4. Develop a workflow that combines design, simulation, and practical testing.
5. Assess the environmental and cost implications of the optimized chassis.

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What You Will Do Step by Step

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1. Review literature on lightweight chassis design and topology optimization basics.
2. Model a hybrid electric vehicle chassis geometry in a CAD tool.
3. Apply topology optimization to reduce weight while preserving strength and safety margins.
4. Select and test composite material options for the load paths identified by the optimization.
5. Run simulations for static and dynamic loading scenarios to verify performance.
6. Prototype critical sections and perform basic physical tests or surrogate testing.
7. Compare results with conventional chassis designs in terms of weight, stiffness, and cost.
8. Document design decisions, trade-offs, and recommendations for further work.

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Expected Outcome

A lighter, cost-effective chassis concept that meets safety standards, with a documented process for applying topology optimization and composite materials in similar designs.