Boosting EV Efficiency Through Stronger, Lighter Joints
Lightweighting with PEM® Fasteners: Boosting EV Efficiency Through Stronger, Lighter Joints
As electric vehicles (EVs) evolve, automotive manufacturers are increasingly focused on lightweighting—the practice of reducing a vehicle's weight without compromising its strength. Lighter vehicles not only enhance efficiency and extend battery range but also support the broader push toward sustainability. One area of particular interest is the shift from traditional, heavier materials to lighter, high-strength alternatives like thin, high-tensile steel and aluminum alloys. However, achieving strong, reliable threaded joints in these materials can be challenging. This is where PEM® fasteners come into play, offering effective solutions to enable lightweighting while maintaining the structural integrity required for high-performance EV applications.
Traditional Challenges in Mechanical Joints and the Need for Lightweighting
Traditionally, components like automotive seat brackets are made from stamped steel, which provides durability but can be weight-intensive. The weight of these materials adds up, impacting both EV performance and range. The industry’s move toward thinner, high-tensile steel or aluminum alloys addresses these weight concerns, but it introduces a new challenge: creating secure mechanical joints in thinner materials while maintaining strong, threaded connections.
For example, replacing a bracket previously made from standard steel with thin, high-strength steel or aluminium alloy may reduce weight but requires an alternative approach to threading. These materials can’t simply be tapped in the traditional way without risking compromised strength or wear.
PEM® Fasteners: Enabling Lightweighting with Strong Mechanical Joints
PEM® fasteners, specifically S™-nuts and other self-clinching options, allow for the creation of robust threaded joints in thin, lightweight materials. These fasteners integrate directly into thin sheets, such as high-strength steel and aluminum alloys, providing a strong, reliable thread without the need for thick material. Let’s explore the advantages of using PEM® fasteners in EV manufacturing:
Compatibility with Thin, High-Strength Steel: High-tensile steels, such as those rated at 700 MPa, are becoming popular in EV manufacturing due to their strength-to-weight ratio. However, tapping directly into these thin steels can be difficult and less reliable. With PEM®’s self-clinching S-nuts, manufacturers can achieve the necessary thread strength without adding bulk or compromising material integrity.
Enhanced Strength in Aluminum Alloys: Aluminum alloys are another preferred material for lightweighting, as they offer substantial weight savings over steel. However, they traditionally don’t hold threads as effectively as steel. PEM® fasteners solve this issue by embedding a strong threaded connection directly into the aluminum. This allows engineers to confidently incorporate aluminum in places where strong, threaded connections are essential—such as seating brackets—without risking structural failure.
Structural Benefits from Corrugated and Folded Thin Materials: For components requiring additional structural integrity, thin, high-strength steel can be folded into corrugated shapes, significantly boosting its load-bearing capacity. Using PEM® fasteners in these corrugated materials ensures that threads remain durable and secure, even in applications with high-stress demands.
Real-World Applications in EVs: From Seating Brackets to Battery Housings
In EV manufacturing, the use of PEM® fasteners extends beyond just the brackets and joints. Here are some key applications where PEM® fasteners enable lightweighting:
Seating Brackets: By integrating PEM® fasteners into thinner, high-strength steel or aluminum brackets, manufacturers can reduce the weight of seating structures without compromising passenger safety or comfort. The ability to create secure threads in these lighter materials is crucial for maintaining structural integrity in seating assemblies, which undergo considerable stress. Battery Housings and Enclosures: Battery housings require materials that can hold up under stress and protect the battery pack in case of an accident. PEM® fasteners allow for strong, mechanical joints in lightweight materials, reducing the weight of the battery housing and improving overall EV efficiency.
Chassis and Structural Components: In areas where high tensile strength is required, thin steel with PEM® fasteners offers a strong and lightweight alternative to thicker materials. This combination ensures a sturdy framework without adding unnecessary bulk.
Advantages of Using PEM® Fasteners for Lightweighting
Reduction in Weight: PEM® fasteners allow for a reduction in overall vehicle weight, which directly translates to greater battery efficiency and extended range. Using PEM® fasteners in place of traditional tapped threads in thicker materials allows engineers to move to thin, lightweight materials without sacrificing thread strength.
Increased Material Flexibility: With PEM® fasteners, manufacturers have more freedom to choose materials based on weight and strength rather than compatibility with traditional threading. This opens up new possibilities for innovative designs in lightweighting without the limitations of tapping and threading.
Improved Reliability and Durability: PEM® fasteners are designed to provide a secure, long-lasting hold, which is especially important in EVs where components need to endure high levels of vibration and stress. This durability contributes to the overall reliability of the vehicle and reduces maintenance needs over time.
Conclusion: PEM® Fasteners as Enablers of EV Lightweighting
As EV manufacturers continue to prioritize lightweighting to improve range and efficiency, PEM® fasteners play a vital role in enabling this shift. By facilitating strong mechanical joints in thin, high-strength steel and lightweight aluminum alloys, these fasteners unlock new potential for advanced, lightweight EV designs. In a world where every gram counts, PEM® fasteners help automotive engineers achieve the perfect balance between durability, weight savings, and performance. The result is a smarter, lighter, and more efficient electric vehicle, ready to meet the demands of the next generation of sustainable transportation.
For more information on how our specialized solutions can benefit your EV applications, contact us at PennEngineering®. Let's drive the future of electric vehicles together.
Also in this series:
Cutting Energy Waste in ICEs and EVs: The Hidden Efficiency Challenge
Efficient Joining of New Materials: Fastener and Installation Solutions for Aluminum Busbars in EVs