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Building lighter components with 3D printing

Researchers in France are developing a new way to use additive manufacturing (AM) for EVs, writes Nick Flaherty. Renault Group is working with French research group CEA-Liten on a complex mesh structure that can be produced in a single, 3D-printing AM stage to produce components with adaptive mechanical behaviour.

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Electron beams offer faster, more precise welding

Cambridge Vacuum Engineering (CVE) is working with Ford on automating electron-beam welding, writes Nick Flaherty. The EB-eDrive project will examine how to scale up electron-beam welding for joining copper and aluminium components in electric motors.

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New standard proposed for e-mobility power management

Intel is proposing a standard for power management across an e-mobility platform, based on its work in the computer sector, writes Nick Flaherty. It is taking a whole vehicle energy-management approach, inspired by PC equipment. It is looking to apply these concepts to an electric vehicle (EV) platform for the first time to provide a central energy management standard.

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Pilot line provides double the battery density of lithium ion

Nissan has shown its pilot line for all-solid-state batteries, writes Nick Flaherty. The Yokohama Plant in Kanagawa Prefecture, Japan, will supply EVs in 2028, which means the platforms are currently under design.

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Weight-saving composites for electric buses

Exel Composites in Finland has developed a large-scale composite process for electric buses, writes Nick Flaherty. It has secured a project with Foton Bus and Coach in China to supply glass-fibre composites, which will reduce the maintenance requirements and weight of the vehicles due to their corrosion-resistant and lightweight properties.

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Dynamic charging e-rail powers mining trucks

A patented power rail-connection system is boosting the use of EVs in mining, writes Nick Flaherty. BluVein in Australia has been working with Hitachi Energy on the dynamic charging system to deliver battery-electric haul trucks up to 400 Mt.

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All-solid-state sodium batteries closer to practical use

Researchers in Japan have developed a process that produces a sulfide solid electrolyte with the world’s highest sodium ion conductivity, writes Nick Flaherty. The synthesised material, developed at Osaka Metropolitan University, is a key contender for all-solid-state sodium batteries. The solid electrolyte, Na2.88Sb0.88W0.12S4, has a sodium ion conductivity about 10 times higher than required for practical use and a glass electrolyte with high reduction resistance.

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First airfield-to-airfield eVTOL flight with recharging

Skyfly and AeroVolt are working on the first electric vehicle take-off and landing (eVTOL) flight in the UK between two airfields with electric charging points, writes Nick Flaherty. AeroVolt is installing a network of aircraft smart chargers around the UK at airports and aerodromes. It currently has five operational sites and aims to have 24 running by the time deliveries of the Skyfly Axe eVTOL begin in 2025, with plans in place for over 60 sites.

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NASA tech lands for brake systems

Orbis Brakes in the US has licensed a NASA-patented technology for lightweight braking systems in electric vehicles, writes Nick Flaherty. The revolutionary brake disc design is at least 42% lighter than conventional cast-iron rotors, with performance comparable to much more expensive carbon-ceramic models.

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Resting boosts lithium-metal battery cells

Researchers have found a key way to extend the life of next-generation lithium-metal batteries, writes Nick Flaherty. Lithium metal cells can double the range of EVs on a single charge and this is a crucial technology for solid-state cells. The researchers at Stanford University found a low-cost approach, which was to simply drain the battery and let it rest for several hours. This restored battery capacity and boosted overall performance.