The battery enclosures used in the first wave of EVs to hit the market after 2010 were designed to be sealed firmly shut. This took to an extreme the need to be impenetrable, crash proof, fireproof, waterproof and tamper-proof and resulted in mostly irreparable batteries and recycling processes that frequently require people in protective clothing using crow bars to prise open the enclosures protecting these very heavy, high-voltage machines. But technologies and production strategies are fast-evolving.
Digital tools are playing a major part in innovating press shop operations with data gathering and AI increasing the visibility and efficiency of the forming process
In our AMS Evolution Livestream experts from ArcelorMittal and Gestamp tackle EV production challenges and explain how digital tools, new technologies, processes and materials innovations could help solve some key issues
Hear expert insights into the development and production of high volume electric vehicle architectures, and how these are driving innovation in manufacturing processes and efficiencies, featuring Gestamp’s North America R&D director Paul Belanger and ArcelorMittal head of automotive steel solutions Jérôme Favero.
Form and function: Developing production processes and structures for electric vehicle architectures
The new electric vehicle architectures are also continuing to evolve as vehicle makers strive to find the optimum balance between platform flexibility, while also being viable for high-volume production. To get some insights in to this ongoing process AMS spoke with Paul Belanger, Gestamp’s R&D Director for North America
The company is planning to source aluminium with significantly reduced CO2 emissions from Rio Tinto’s hydro-powered operations in Canada, starting next year. Compared to conventionally manufactured aluminium, this approach can save around 70% of CO2 emissions
Mercedes-Benz to collaborate with Norwegian aluminium producer Hydro to reduce the CO2 footprint of aluminium in the automotive supply chain
The pioneering initiative will reduce the resource, energy and emissions intensity of a car’s lifecycle since some components can have a second life as used, reconditioned parts.
Innovations in vehicle body and module architectures are enabling more sustainable production. Experts from REE Automotive, Magswitch and others discuss opportunities in the next AMS Livestream.
Automakers crimp energy use and reluctantly turn to coal and oil but options may be more limited for component and material suppliers upstream.
In this livestream, learn how OEM start-ups can short time to market in manufacturing and re-engineer body structures, featuring the head of manufacturing at Volta Trucks and ArcelorMittal.
France’s Renault and Chinese component maker, Minth Group have announced a joint venture to produce casings to house batteries in electric vehicles.
Volvo, Polestar and SSAB ponder how to wring out CO2 from materials now that the internal combustion engine’s fate is virtually sealed.
The light metal foundry at the BMW components plant in Landshut is using multi-plate die casting technology, which offers function-optimised component design and design of the required sprue positions and flow paths
The aluminium die-casting process could revolutionise body construction. Professor Wolfram Volk, the department head for forming technology and casting at the Technical University of Munich, explains the advantages and disadvantages of so-called ‘mega’- or ‘gigacasting’.
In the coming years, Volvo Cars will be investing SEK 10 billion ($1.1 billion) into its manufacturing plant in the Torslanda province of Gothenburg, Sweden, as preparation for the production of the next generation of fully electric cars.
One of the key pillars of Volvo’s investment in electric vehicles will be the application of aluminium megacasting to produce large structural parts. Mikael Fermér, solution architect for vehicle platforms at Volvo Cars, explains the significance of this change for EV production.
Novelis is investing $365m to construct an advanced aluminium recycling centre for the automotive industry in North America. The new recycling facility will be built adjacent to Novelis’ existing automotive finishing plant in Guthrie, Kentucky.
Upgrades to the Bedford plant are to support production of drive unit castings for new Silverado all-electric pickup. The facility has already launched drive unit castings for GMC Hummer EV pickup and SUV
Electric vehicles battery enclosures are increasing overall vehicle weight, with lightweight materials for structural components, such as castings, can offset the rise. Rio Tinto’s Jerome Fourmann tells Nick Holt about new opportunities and production innovations