Watch Now: Shaping the future: How electric vehicles are driving manufacturing decisions

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Explore electric vehicle (EV) architecture design and manufacturing complexities, from flexible platforms to battery integration challenges.

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Updated 24 January 2024 with on-demand video

Shaping the future: how electric vehicles are driving manufacturing decisions on architectures, materials and battery integration 

In our latest Premier Livestream, insights were shared by experts from Gestamp and ArcelorMittal on how decisions in electric vehicle design and manufacturing are being influenced by new powertrain layouts and battery integration choices. 

The challenges of integrating the battery pack into the vehicle body, particularly in the bodyshop, is adding complexity to the body assembly process. OEMs are aiming to simplify body architectures and battery integration, balancing factors such as light weight, durability, sustainability and cost. 

The Livestream looked at key differences in electric vehicle structures, challenges in multi-material bodies, the need for production flexibility in bodyshops, materials, and manufacturing considerations for battery integration, supporting new technologies, sustainability in the design/engineering process, trends in EV architecture, and ongoing developments in the EV design and manufacturing process. 

Key points covered:

  • OEMs prioritising flexible platforms in EVs for diverse segments and brands
  • The current trend where OEMs are looking to simplify body assembly and production optimise efficiency
  • Integration of battery packs into vehicle bodies poses challenges, requiring advanced engineering for crash protection systems, which adds cost and complexity to the manufacturing process
  • Manufacturers managing elements such as platform design, battery integration methods, and material choices crucial for balancing vehicle bodies for weight, durability, sustainability, and cost
  • Market remains highly dynamic, with continuing changes in battery chemistries and configurations, and the potential impact of technologies like hydrogen contributing to an ongoing evolution of EV architectures


Jesse Paegle round headshor

Jesse Paegle
Automotive Steel Solution Director 

Jesse has worked in the mining and automotive industries since 1997. His experience has given him a good understanding of the entire automotive supply chain and in his current position he’s responsible for steel solutions developments including BIW, Battery pack and chassis components.  

Paul Belanger
R&D Director North America

Mr. Belanger leads a team of Body engineers developing products and new technologies from Gestamp’s North American R&D Center. Paul started his career in the steel industry before moving into automotive with Chrysler’s Materials Engineering and Ram Truck Body Engineering. Later, at GM, he headed a Manufacturing Engineering team providing expertise with critical stampings and complex assemblies. Mr. Belanger has been using his 30+ years of automotive body and materials engineering experience to drive the development and optimum application of advanced sheet metal products into automotive vehicle production. 


Nick Holt
Automotive Manufacturing Solutions, Ultima Media

With over 20 years experience covering the automotive industry, Nick is responsible for editorial across Automotive Manufacturing Solutions. He has gained wide experience in automotive production operations, visiting OEM and tier supplier factories in Europe, India, China and the US.

Hosted in Partnership With ArcelorMittal

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At ArcelorMittal, our goal is to help build a better world with smarter steels. Steels made using innovative processes which are more efficient, use less energy, and emit significantly less carbon. Steels that are cleaner, stronger and reusable. Steels for electric vehicles and renewable energy infrastructure that will support societies as they transform through this century.

We foster this culture of innovation by putting research and development at the heart of our operations. We have some of the best and brightest people in the business – engineers who work for us because they get to tackle the most complex of problems.


Upcoming Events

Design 4 Production  |  15 May 2024  |  Munich, Germany

Bringing together automotive designers and engineers, manufacturing engineers and plant leaders the event will delve into the transformative strategies and advancements shaping the future of vehicle design, development, and production.

Automotive Evolution North America Conference  |  30 - 31 October 2024  |  Dearborn, MI

The second Automotive Evolution North America conference continues to empower manufacturing leaders and experts as they dive deeper into opportunities in localisation, evolving skills, and advanced technologies amid the shift to electrification and sustainability.

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