With the trend toward lightweighting in new energy vehicles, how can hardware products achieve both weight reduction and safety?
Publish Time: 2025-09-23
Driven by the "dual carbon" goals, new energy vehicles are accelerating their development toward longer driving range, higher efficiency, and enhanced safety. Lightweighting, as one of the core pathways to improving energy efficiency, has become a key strategy in vehicle development. In this trend, hardware products in new energy vehicles are no longer simply connecting, supporting, or fixing components in the traditional sense; they are now deeply involved in optimizing the overall vehicle structure and improving its performance. Achieving significant weight reduction while ensuring structural strength, crash safety, electrical insulation, and durability has become a core challenge facing hardware systems in new energy vehicles. Through material innovation, structural optimization, and upgraded manufacturing processes, modern hardware products are achieving both weight reduction and safety breakthroughs.1. Widespread Use of High-Strength, Lightweight MaterialsTraditional fuel vehicle hardware often uses ordinary carbon steel. While this steel offers low cost and high strength, its high density hinders weight reduction. New energy vehicles, on the other hand, widely utilize lightweight, high-strength materials such as high-strength aluminum alloys, magnesium alloys, titanium alloys, and high-strength stainless steel. Aluminum alloy, with its density only one-third that of steel, high specific strength, and excellent corrosion resistance, is currently the most widely used alternative material. Furthermore, some high-end models are beginning to explore the use of magnesium alloy in non-load-bearing components such as interior brackets and electronic housings, further tapping into the potential for weight reduction.2. Structural Optimization Improves Material EfficiencyModern hardware design extensively utilizes CAE simulation technology, using topology optimization, morphology optimization, and dimensional optimization to eliminate redundant materials while maintaining mechanical properties. For example, topology optimization can transform the traditional solid structure of the mounting bracket on the battery tray into a hollow or lattice-like lightweight design, significantly reducing weight without sacrificing torsional rigidity. Furthermore, the trend toward integrated design is driving the integration of hardware components. Multiple small parts are combined into a single, complex structure, reducing the number of connection points and fasteners while also improving overall structural stability. This "less is more" design philosophy significantly improves material efficiency and achieves the engineering goal of "light yet not weak."3. Advanced Manufacturing Processes Empower High-Performance HardwareAs new energy vehicles demand higher precision, strength, and consistency in hardware, traditional stamping and welding processes are being replaced by more advanced manufacturing technologies. Integrated die-casting is a typical example. Using large dies, multiple aluminum structural components are formed in one go, significantly reducing welds and seams, improving overall rigidity and sealing, while also reducing weight and assembly costs. Furthermore, high-precision joining processes such as laser welding and friction stir welding ensure the long-term reliability of aluminum alloy hardware in high-temperature and vibration environments. Surface treatment technologies such as anodizing, micro-arc oxidation, and Dacromet coating not only enhance corrosion resistance but also improve wear resistance and insulation, meeting the specific requirements of new energy vehicle high-voltage electrical systems.4. Functional Integration Promotes System-Level Weight ReductionNew energy vehicle hardware is evolving from single-function to multi-functional integration. For example, the battery pack housing is not only a structural support component but also integrates cooling channels, high-voltage insulation, and collision energy absorption structures. Motor end cap hardware also incorporates sealing, heat dissipation, and electromagnetic shielding. This multifunctional integrated design reduces the use of additional components, achieving weight reduction at the system level. Furthermore, the use of lightweight fasteners also contributes to weight savings through detailed improvements.5. Simultaneous Enhancement of Safety PerformanceWeight reduction must never come at the expense of safety. In the lightweighting process, new energy vehicle hardware consistently prioritizes crash safety, battery protection, and electrical isolation. For example, the battery side beams utilize a high-strength aluminum alloy with an energy-absorbing structure to effectively absorb impact energy in side collisions. High-voltage connector hardware terminals feature anti-misinsertion and anti-loosening features, and IP67 or higher protection ratings, ensuring failure resistance in extreme environments. Through rigorous bench testing, crash testing, and durability verification, modern hardware achieves lightweighting while also outperforming even traditional designs in safety.In summary, new energy vehicle hardware products are striking a new balance between lightweighting and safety through material upgrades, structural innovations, process advancements, and system integration. They are not only drivers of weight reduction but also guardians of safety.
