The Israeli company will reduce the weight of future electric carsNovember 6, 2020
Plasan has developed a new lightweight body made from carbon and composite.
A new lightweight CFRP body structure could improve the way electric vehicles are built in the next decade. Developed by Israeli defense company Plasan, the new technology offers a weight reduction of up to 45% over a steel body and 20% over an aluminum body. Plasan has already presented its achievement to global equipment manufacturers and motorsport companies.
“We hope that in two to three years, components will be produced using our technology, and in a few years, a full body will be produced,” said chief designer Nir Kan.
Plasan technology is based on special beams of carbon fiber with carbon filaments continuously distributed along the entire length of the pipe walls, resulting in very strong, rigid, but lightweight structural elements. Each beam is connected to composite body panels to form semi-structured body sides, floor and roof. Then these elements are connected by metal “knots”. The assemblies are made of extruded aluminum in two pieces to speed up assembly.
Plasan believes its design is a breakthrough because the bodies can be built using existing production line equipment and using the same core technologies as conventional one-piece steel structures.
“We really see the possibility of large-scale production of automobiles – this is not limited to defense or motorsport – with possible annual production rates in the hundreds of thousands per year,” said Ronen Berger, head of composite materials at Plasan.
While carbon fiber body technology is relatively expensive, Plasan estimates that the cost of saving every kilogram of weight in an electric vehicle is worth $ 10 per kilogram.
“This makes it more cost-effective than other efficiency gains or the range of electric vehicles,” Kahn said.
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