International Journal of Science, Engineering and TechnologyAuthors: Research Scholar Abhinav Singh Dangi, Associate Professor Dr. Arun Kumar Yadav
Abstract: The increasing demand for energy-efficient and sustainable transportation has accelerated the development of lightweight electric vehicles. Vehicle weight plays a significant role in determining battery performance, driving range, energy consumption and overall vehicle efficiency. This study focuses on the lightweight design and optimisation of an electric vehicle chassis using advanced structural analysis and lightweight material strategies. The research reviews the application of lightweight materials such as aluminium alloys, magnesium alloys, high-strength steel and composite materials for reducing vehicle mass while maintaining structural strength and safety. Finite Element Analysis (FEA) and topology optimisation techniques are studied to improve chassis stiffness, load distribution and durability, and the relationship between lightweighting, energy efficiency, sustainability and intelligent chassis technologies is examined. Twelve studies published between 1998 and 2026 are reviewed and organised into three themes covering lightweight materials and design strategies, chassis optimisation and structural analysis, and energy efficiency with intelligent chassis performance. The reviewed evidence is consolidated into comparative tables that map each study to its focus, method, principal finding and limitation, alongside a qualitative comparison of candidate lightweight materials and a summary of the structural analysis methods reported. Five research gaps are identified and mapped to corresponding research directions. The findings indicate that optimised lightweight chassis structures can reduce vehicle weight, improve energy efficiency, enhance battery performance and increase driving stability, contributing toward the development of efficient, safe and sustainable electric vehicle systems.
