EV Chassis & Lightweighting

Description

This EV Chassis and Lightweighting eBook from 3D-LABS is written for engineers and students who want a clear, practical reference they can apply immediately.

EV Chassis & Lightweighting is a practitioner-level engineering book covering electric-vehicle structure — aluminium space frames, multi-material joining and composite battery enclosures. It treats lightweighting as a structural problem with crash, stiffness, durability and manufacturing constraints attached, rather than as a material substitution exercise, and works each decision through to a joint specification and a cost per kilogram saved.

What format does this book follow and what standards does it reference?

Chapters move from load case to structural concept to joint design, with worked calculations at each step. Standards and test references include AIS-098 and UN R94/R95 for frontal and side impact, AIS-038 Rev 2 for electrical safety after impact, IS 733 and the EN 573/755 series for aluminium alloy and extrusion designation, and IEC 60529 for enclosure ingress protection.

How is an aluminium space frame designed and joined?

Space-frame design is developed from load paths: torsional and bending stiffness targets, node design where extrusions meet, and section selection within extrusion-press limits on circumscribing circle and wall thickness. Joining covers MIG and TIG welding with heat-affected-zone strength loss quantified, friction stir welding, self-piercing rivets and structural adhesive, including the galvanic isolation needed where aluminium meets steel.

What does the book cover on composite battery enclosures?

Enclosure design is treated end to end: laminate selection in SMC, GFRP and hybrid constructions, stiffness and crush requirements, flame and thermal-runaway containment behaviour, sealing to IP67 with a serviceable gasket, EMI shielding where a non-conductive housing removes it, and the attachment scheme that carries pack mass into the structure through a limited number of hard points.

How does the book quantify whether lightweighting is worth it?

Every mass reduction is costed. The book sets out cost per kilogram saved for each material and process route, the secondary mass saving that follows from a lighter structure, and the effect on range, pack size and payload. A decision framework compares a cheaper heavier structure with a larger pack against a lighter expensive structure with a smaller pack, at a given production volume.

How do I access this book after purchase?

eBook PDF: Instant download — a secure download link is delivered via email and your 3D-LABS account dashboard immediately after payment confirmation. No shipping wait. Lifetime access included — re-download anytime. Paper Book: Printed and shipped to your delivery address in India. Expect standard courier delivery timelines.

Contents

1. EV Structure: What Changes When the Pack Is Structural — p. 1–21
2. Load Cases, Stiffness Targets and Durability Requirements — p. 22–42
3. Material Options: Steel, Aluminium, Magnesium, Composite — p. 43–63
4. Aluminium Extrusion Design and Press Limits — p. 64–84
5. Space Frame Topology and Node Design — p. 85–106
6. Welding Aluminium and Heat-Affected-Zone Strength — p. 107–128
7. Mechanical and Adhesive Joining, Multi-Material Interfaces — p. 129–150
8. Corrosion and Galvanic Isolation — p. 151–172
9. Composite Battery Enclosures: Laminate and Crush Design — p. 173–194
10. Sealing, Ingress Protection and EMI Shielding — p. 195–216
11. Crashworthiness and Post-Impact Electrical Safety — p. 217–238
12. Topology Optimisation, Cost per Kilogram and Reference Tables — p. 239–260

What’s Included

An instant PDF download covering the core concepts, practical examples, and key references — ready to read on any device.

Related Reading

• Materials Selection by Failure Mode — A Designer’s Guide
• FEA for Practising Engineers — ANSYS Workbench Edition
• Applied Strength: Tank, Vessel and Skid Edition

Download the EV Chassis & Lightweighting e-book from 3D-LABS — instant PDF access with lifetime re-downloads.

About EV Chassis & Lightweighting

EV Chassis & Lightweighting is part of the 3D-LABS Bikes & EV series — a focused e-book library for automotive engineers, EV designers, and electric mobility researchers. This title covers electric vehicle powertrain, battery technology, charging infrastructure, motor design, and sustainable mobility, with worked examples and industry-current best practices drawn from real electric mobility projects.

Written by practising 3D-LABS engineers and reviewed by senior specialists, EV Chassis & Lightweighting is designed to move you from concept to competence quickly — not to be a comprehensive academic reference, but a working reference you actually use.

Who EV Chassis & Lightweighting is for

EV Chassis & Lightweighting is written for automotive engineers, EV designers, and electric mobility researchers. If you are:

• An early-career engineer wanting to accelerate your practical knowledge in electric mobility.
• An experienced practitioner looking for a compact reference on current practices.
• A student preparing for engineering exams, interviews, or your first professional role.
• A manager or team lead wanting to level-set your team on electric mobility fundamentals.

Then EV Chassis & Lightweighting will earn its price back in the first project or exam you apply it to.

What is included in your download

• The complete PDF e-book — DRM-free, fully searchable, print-friendly formatting.
• Worked examples — real-world calculations, drawings, or case studies interspersed through the text.
• Reference charts and tables — quick-lookup material you will return to on the job.
• Further reading recommendations — curated pointers to codes, standards, and complementary resources.
• Free updates — when we revise the book, you get the updated PDF at no extra cost. We notify you by email.

Pricing and delivery

EV Chassis & Lightweighting is priced at ₹4,740 (USD equivalent shown in cart). Delivery is instant — after payment, the download link is emailed to you and available in your account. No subscriptions, no hidden fees, no expiring access.

Payment methods: Cashfree (Indian customers) or PayPal International (customers outside India). Bulk licensing available for corporate training programmes and educational institutions — contact sales@3d-labs.com.

How to get the most out of EV Chassis & Lightweighting

1. Read the introduction and structure first — every book has a "how to use this book" section that maps chapters to the reader you are.
2. Work through the examples with pen and paper — passive reading is 10% retention; working the calculation yourself is 70%+.
3. Cross-reference with the 3D-LABS spreadsheet library — 686 Excel calculation tools that pair naturally with our e-books.
4. Apply the concepts to a real project immediately — the book will pay for itself the first time you avoid a design error.
5. Come back to the book after 6 months — with real project experience, you will read the same chapters differently.

Related titles and services

Readers of EV Chassis & Lightweighting typically also work with:

• Other titles in the Bikes & EV book series — currently 18 titles.
• The FEA Services — for projects where you need experienced electric mobility engineers directly.
• Our 686 engineering calculation spreadsheets — Excel tools that complement the theory in this book.
• Our online training courses — instructor-led programmes on electric mobility topics.

Frequently asked questions

What format is EV Chassis & Lightweighting delivered in?

EV Chassis & Lightweighting is delivered as an instant-download PDF file. The PDF is DRM-free, works on any device (desktop, tablet, phone, e-reader), and is fully searchable. Print-friendly formatting so you can print for offline reading.

How is this different from a paper textbook?

This e-book is a focused, practical guide — targeting a specific engineering skill or knowledge area. Unlike a 600-page academic textbook, it moves quickly to real-world applications with worked examples, industry practices, and current code references. Priced accordingly.

Who wrote this book?

Books in the Bikes & EV series are authored by 3D-LABS engineers and reviewed by senior specialists in the field. Every author has hands-on industry experience — this is not academic theory, it is applied practice from working engineers.

Can I use the material for teaching or training?

Purchase includes single-user rights. For classroom use, corporate training programmes, or bulk licensing, contact us at info@3d-labs.com — we offer institutional licensing and custom-branded editions for training programmes.

What if the content does not meet my expectations?

We offer a 7-day satisfaction guarantee. If EV Chassis & Lightweighting does not deliver the value you expected, email us within 7 days of purchase for a full refund. No questions asked — we would rather have satisfied customers than unhappy ones.

About 3D-LABS engineering e-books

EV Chassis & Lightweighting is one of 115 titles in the 3D-LABS e-book library — the largest collection of practitioner-authored engineering e-books available anywhere, spanning 14+ series from engineering fundamentals to future technology and urban air mobility. Every book is written and reviewed by 3D-LABS engineers who use the concepts daily on real client projects across the globe.

Browse the full e-book library, or explore other content options: 686 spreadsheets, 19 online courses, or our full engineering services.