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World Electric Vehicle Journal is published by MDPI from Volume 9 issue 1 (2018). Articles in this Issue were published by The World Electric Vehicle Association (WEVA) and its member the European Association for e-Mobility (AVERE), the Electric Drive Transportation Association (EDTA), and the Electric Vehicle Association of Asia Pacific (EVAAP). They are hosted by MDPI on as a courtesy and upon agreement with AVERE.
Open AccessArticle

Optimal Lightweighting in Battery Electric Vehicles

Paul Scherrer Institut, CH-5232 Villigen PSI, Switzerland
Massachusetts Institute of Technology, Cambridge, MA 0213 9-4307, USA
Author to whom correspondence should be addressed.
World Electr. Veh. J. 2012, 5(3), 751-762;
Published: 28 September 2012
PDF [865 KB, uploaded 17 May 2018]


This paper presents an analytic solution to find the optimal amount of lightweighting in a battery electric vehicle (BEV). The additional cost of lightweighting is traded off against the cost savings due to the smaller battery and motor required at constant performance and range. Current technology cost estimates indicate that for a medium sized BEV, optimal glider mass reduction is on the order of 450 kg in 2012 leading to estimated manufacturing cost reductions of 4.9%. Declining powertrain costs are expected to reduce the importance of lightweighting in minimizing BEV cost in the future, and rising electricity costs to increase the gap between the optimal solutions based on minimizing manufacturing versus total costs. The results are strongly dependent on the future development of lightweighting, battery, and electricity costs. The sensitivity of the optimal mass reduction to these critical parameters has been evaluated, and is shown to increase over time.
Keywords: BEV (battery electric vehicle); cost, optimization; light weighting BEV (battery electric vehicle); cost, optimization; light weighting
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).

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Hofer, J.; Wilhelm, E.; Schenler, W. Optimal Lightweighting in Battery Electric Vehicles. World Electr. Veh. J. 2012, 5, 751-762.

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