Can Extruded Aluminum Profiles Reduce Weight in Electric Vehicle Chassis?

Extruded aluminum profiles are revolutionizing electric vehicle chassis design by enabling weight reductions¹ of 30-50% compared to traditional steel structures while maintaining structural integrity² and safety performance. At our manufacturing facility, we’ve helped numerous EV manufacturers implement aluminum extrusion solutions that not only lighten the vehicle but also enhance overall performance and range efficiency.

The unique combination of aluminum’s natural lightness³ (one-third the density of steel) with extrusion’s design flexibility⁴ allows engineers to create optimized structures⁵ that put material exactly where it’s needed, eliminating unnecessary mass while maintaining critical strength characteristics. This approach has become particularly valuable in EV design where every kilogram saved translates directly into extended range and improved efficiency.

How much weight can actually be saved?

The replacement of steel components with extruded aluminum profiles⁶ typically achieves 40-50% weight reduction in chassis components while maintaining equivalent or superior structural performance. This dramatic weight saving comes from aluminum’s inherent properties combined with the ability to create optimized profiles that eliminate unnecessary material.

Real-world examples demonstrate these savings:

• Tesla Model S achieved approximately 40% weight reduction in its aluminum-intensive body and chassis compared to equivalent steel structures
• BYD’s electric bus program realized 1.2 tons of weight reduction by switching from steel to aluminum bodies
• Range extension of 2.5km for every 10kg of weight reduced in EV applications

These savings are particularly significant in EVs where battery weight⁷ already adds substantial mass to the vehicle, making chassis lightweighting essential for maintaining acceptable overall weight.

What makes extrusion ideal for chassis applications?

The aluminum extrusion process allows creation of complex, multi-void profiles that optimize strength-to-weight ratios while integrating multiple functions into single components, reducing part count and assembly complexity. This capability is particularly valuable in EV chassis design where space efficiency and weight distribution are critical.

Key advantages of extruded profiles:

• Design flexibility: Complex cross-sections with varying wall thicknesses
• Functional integration: Channels for wiring, cooling, and structural reinforcement
• Material efficiency: Minimal waste compared to machining from solid billet
• Consistency: Continuous production of identical profiles with tight tolerances

These characteristics make extrusion particularly suitable for longitudinal members, battery enclosure frames, and crash management systems⁸ where controlled deformation and energy absorption⁹ are required.

How does aluminum extrusion enhance battery protection?

Extruded aluminum profiles create exceptionally strong yet lightweight battery enclosures that provide crucial protection for EV battery systems while contributing to overall vehicle structural integrity. The battery enclosure is one of the most safety-critical components in any EV, and extrusion offers unique advantages for this application.

Modern aluminum battery enclosures utilize:

• Multi-chamber profiles that separate cells while providing cooling channels
• Integrated mounting features that secure battery modules without additional brackets
• Crush zones designed to deform predictably in impact scenarios
• Thermal management channels that help maintain optimal battery temperature

The natural thermal conductivity of aluminum (167-201 W/m·K) makes it particularly suitable for battery applications where temperature management is crucial for both performance and safety.

What about crash safety and durability?

Properly engineered aluminum extrusions provide exceptional energy absorption in crash scenarios, with aluminum structures absorbing up to 50% more energy than equivalent steel components while weighing significantly less. This makes them ideal for critical safety structures in EV chassis.

These characteristics are particularly important in EVs where the battery mass must be properly managed and protected during impact events.

How does extrusion support manufacturing efficiency?

The extrusion process enables high-volume production of complex profiles with minimal secondary operations, significantly reducing both part count and assembly time compared to traditional stamped and welded structures. This manufacturing efficiency¹⁰ translates to both cost savings and quality improvements.

Manufacturing benefits we’ve implemented for clients:

• Reduced component count: Up to 70% fewer parts compared to stamped assemblies
• Simplified assembly: Profiles designed with integrated joining features
• Tighter tolerances: ±0.1mm consistency in profile dimensions
• Material optimization: Variable wall thickness within single profiles

These efficiencies are particularly valuable in EV production where reducing complexity helps offset the higher material costs of aluminum versus steel.

What are the challenges and solutions?

While aluminum extrusion offers significant advantages, successful implementation requires addressing material costs, joining challenges¹¹, and design optimization to maximize the weight-saving potential while maintaining structural performance. Through our experience with EV manufacturers, we’ve developed solutions to these common challenges.

Common challenges and our approaches:

• Material cost premium: Offset by reduced assembly costs and performance benefits
• Joining compatibility: Specialized techniques for aluminum-to-aluminum and aluminum-to-steel connections
• Design optimization: Advanced simulation and prototyping to optimize profiles for specific applications
• Recycling infrastructure: Development of closed-loop recycling systems for production scrap

These challenges are manageable with proper design and engineering, and the benefits typically outweigh the difficulties for most EV applications.

Ready to explore aluminum extrusion for your EV chassis?

Our engineering team combines extensive aluminum extrusion expertise with EV-specific design experience to help manufacturers implement lightweight chassis solutions that enhance performance, range, and safety. Contact us to discuss how extruded aluminum profiles can reduce weight in your electric vehicle chassis while maintaining structural integrity and safety performance.

Why EV manufacturers choose our extrusion capabilities:

• Custom profile design and optimization
• High-volume extrusion production capacity
• Full testing and validation services
• Multi-material joining expertise
• Complete recycling and sustainability programs

Don’t let weight hold back your EV performance – let’s discuss how aluminum extrusion can lighten your chassis and extend your range.