Electric vehicles need improved range to ensure wider acceptance, and one of the biggest influences on range is vehicle weight. Sheet metal suppliers can fill the need for lightweight components. Getty Images

The battery electric vehicles (BEV) industry is offering new and exciting opportunities for sheet metal fabricators and stamping manufacturers to produce quality, lightweight components. As BEVs gain market share, manufacturers will need to address issues with mineral supply chains and vehicle curb weight, as vehicle weight is among the most important factors in BEV efficiency and capability.

As BEVs migrate from novel vehicles to niche vehicles, the industry needs to ensure the BEVs have adequate range, especially since BEV charging infrastructure is in its infancy. And one of the biggest influences on range is vehicle weight. Currently, BEV manufacturers are using lightweight materials, but the batteries are heavy.

Today’s solution to range seems to be adding denser battery capacity. Production improvements over the past 10 years have led to a dramatic reduction in the cost per kilowatt-hour for lithium-ion batteries. This enables manufacturers to add greater battery capacity without negatively influencing vehicle costs.

Adding battery capacity, however, can’t fully compensate for bloated weight. For one, battery researchers agree that future improvements in battery technologies will lead to marginal cost improvements. To achieve acceptable range, manufacturers must do better at reducing the curb weight of current BEVs. For instance, GM’s Hummer three-motor version has an estimated curb weight of 10,000 to 14,000 lbs. Its 200-kwH battery capacity is twice that of Tesla’s, but with less range.

Reducing curb weight to gain acceptable range will need to be an aggressive effort by OEMs, especially given the weight of batteries, safety equipment, and consumer demand for entertainment and comfort amenities.

As BEV sales become a more significant market segment, costs of essential minerals will increase both because of supply and demand and because increased demand will further expose issues in the mineral supply chain.

The issues that will drive a push for even lighter weight components include:

There will be enough economic and social pressure on mineral markets to encourage BEV manufacturers to become more careful and efficient in vehicle components and design. Battery manufacturers are already reducing or eliminating the use of cobalt in cathodes because of its scarcity and unethical mining issues. The increased demand for lithium also will increase the environmental influence of extraction and evaporation.

Addressing BEV range means addressing weight with lightweight components. The opportunity is there now for stampers and other sheet metal component suppliers, and it will continue to grow. Now is the time to look at your shop's goals and prepare to join the lightweight supply chain.

For the electric vehicle market to really take off, vehicle manufacturers have to improve range. To do that, the vehicles need to get lighter.

See More by Bill Frahm

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