One of the biggest design challenges of electric cars is the weight of the vehicle. In many EV models, the battery pack can match the Even for 20-30% of vehicle weight, making many electric cars heavier than their combustion counterparts. Weight differences within the same model lineup can reach several hundred kilograms, depending on battery capacity and vehicle configuration. Electric car manufacturers are working hard to reduce vehicle weight. Most often, interior components, trim, technical covers and aerodynamic elements of the chassis are optimized. Every kilogram matters, and vehicle weight directly affects energy consumption and vehicle range.
The development of electromobility is increasing the demand for manufacturing technologies to reduce the weight of vehicle components. In this area, thermoformed materials are becoming increasingly important.
Why is thermoforming gaining importance in electromobility?
Vacuum Vacuum forming enables the production of large parts with complex geometries at relatively low weight. The process involves heating a sheet of plastic and then forming it into a suitable form using vacuum, pressure or a combination of both methods.
Thermoforming is particularly applicable where the following are required:
- large component areas,
- High geometric stability of the elements,
- good quality of visible surfaces,
- High dimensional repeatability of production,
- The relatively low weight of the component,
- design flexibility.
Vacuum thermoforming is particularly advantageous for large-size components. This technology makes it possible to produce large components from plastic sheets at much lower tooling costs than injection molding technology. This makes it well suited for medium-size batch production and for projects requiring rapid prototyping and design modifications.
Vacuum thermoforming in the EV industry - key applications
In electric cars, thermoformed components are used in many parts of the vehicle structure. We are talking about interior components, as well as technical covers or chassis components.
Components of the vehicle interior
One of the most common applications is for interior components, where not only weight but also aesthetics are important. Among the most common applications for thermoformed components in vehicle interiors are:
- door panels and sides,
- post covers,
- center console components,
- seat backs and interior structural elements.
Importantly, thermoforming makes it possible to create large parts with a uniform surface, and this reduces the number of joints and assembly parts.
Technical covers and functional components
Thermoformed plastics are also widely used in components such as:
- covers for wiring and electrical installations,
- service covers,
- electronic component housings.
In many EV structures, thermoformed plastic components act as lightweight covers for electrical and electronic systems, protecting the installations not only from mechanical damage, but also from environmental factors. In a similar way, in Geo Globe Poland ESD trays used in the transportation of electronics are also being designed.
Underbody guards and aerodynamic components
Another important application area is chassis components, including:
- undercarriage covers,
- wheel arch covers,
- elements to protect the vehicle's systems.
What materials are used in thermoforming components for the EV industry?
The choice of material depends on the function of the component, its location in the vehicle and the durability and safety requirements. In practice, the most common applications in the automotive industry are:
ABS - is one of the most commonly used materials in vehicle interior components, valued for its good surface quality and high impact resistance.
PC/ABS - is a material with improved thermal and mechanical resistance, used in components requiring greater durability and dimensional stability.
PP (polypropylene) - It is used in technical components, covers and components exposed to moisture and chemicals.
HDPE - is a material with both high chemical resistance and very good mechanical strength, and is used very often in technical components and covers.
The production of thermoformed parts is increasingly using recycled materials. W Geo Globe Poland's process is supported by its own plastic recycling lines. This makes it possible to create high-quality components while reducing the carbon footprint.
Thermoforming vs. other manufacturing technologies
In the industry automotive Vacuum thermoforming is one of several technologies used to manufacture plastic components. Injection molding works best for very high production volumes and smaller details with complex geometries.
Vacuum thermoforming is particularly advantageous for:
- large components,
- medium production runs,
- Projects requiring rapid implementation.
A major advantage of this technology is the lower tool preparation costs compared to injection molding. This allows not only a shorter implementation time for new components, but also a significant reduction in production costs.