Lightweight Composite Materials for Electric Vehicles (EVs) and Public and Private Transport

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 470 481
    By

    Sunil Kumar Gupta,

  • Sunil Kumar Chaudhary,

  • Asit Mohanty,

  • Pragyan Paramita Mohanty,

  1. Professor, Department of Electrical and Electronics Engineering, Poornima University, Jaipur, Rajasthan, India
  2. Professor, Department of Electrical Engineering, Galgotias College of Engineering and Technology, Greater Noida, Uttar Pradesh, India
  3. Professor, Centre for Promotion of Research, Graphic Era (Deemed to be University), Clement town, Dehradun, Uttarakhand, India
  4. Assistant Professor, Department of Mechanical Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, India

Abstract

The rapid expansion of the electric vehicle (EV) industry has intensified the demand for battery enclosures that are lightweight, durable, thermally stable, and environmentally sustainable. This study investigates the design and sustainable fabrication of hybrid nanocomposites for advanced EV battery housings. The proposed composite system combines carbon fiber, glass fiber, and graphene nanoplatelets within a bio-based epoxy matrix, resulting in superior mechanical strength, enhanced thermal stability, and excellent flame retardancy.

A comparative life cycle assessment (LCA) indicates a 28% reduction in embodied energy compared to conventional aluminum housings, underscoring the environmental benefits of this innovative material approach. To ensure industrial feasibility, scalable fabrication techniques such as vacuum-assisted resin transfer molding (VARTM) and automated fiber placement (AFP) using recyclable thermoplastics have been explored. These manufacturing processes enable efficient production while maintaining sustainability and performance consistency.

The findings reveal that hybrid nanocomposites can achieve up to 45% weight reduction, improved crash resistance, and enhanced thermal conductivity, all while supporting recyclability. Such characteristics make them an attractive alternative to traditional metallic enclosures, which are heavier and more energy-intensive to produce.

In conclusion, this research demonstrates that hybrid nanocomposites offer a sustainable, high-performance solution for next-generation EV battery systems. By integrating lightweight design with environmental responsibility, the study contributes to the evolution of eco-efficient electric mobility, reinforcing the automotive industry’s ongoing transition toward greener and more energy-efficient technologies.

Keywords: Lightweight Materials; Composite Materials; Electric Vehicles (EVs); Public Transport; Private Transport; Energy Efficiency; Sustainable Mobility.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Sunil Kumar Gupta, Sunil Kumar Chaudhary, Asit Mohanty, Pragyan Paramita Mohanty. Lightweight Composite Materials for Electric Vehicles (EVs) and Public and Private Transport. Journal of Polymer & Composites. 2026; 14(01):470-481.
How to cite this URL:
Sunil Kumar Gupta, Sunil Kumar Chaudhary, Asit Mohanty, Pragyan Paramita Mohanty. Lightweight Composite Materials for Electric Vehicles (EVs) and Public and Private Transport. Journal of Polymer & Composites. 2026; 14(01):470-481. Available from: https://journals.stmjournals.com/jopc/article=2026/view=237025


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Special Issue Subscription Review Article
Volume 14
Special Issue 01
Received 07/10/2025
Accepted 19/11/2025
Published 18/02/2026
Publication Time 134 Days
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