Crashworthiness enhancement of a composite intensive, multimaterial fully- electric urban car

The purpose of this study is to present the activities carried out with the aim to obtain the best-in-class rating (following Euro NCAP protocols) of a subcompact urban electric car, BEHICLE, featuring a composite intensive, multimaterial body-in-white that allows for a total car weight below 600 kg. Lightweighting is ensured via reinforced composite panels, aluminium greenhouse, and energy absorbing thermoplastic composites distributed along the entire bodywork, mechanically joined to form a solid structure. In order to ensure adult occupant protection, apart from a carefully designed passenger compartment, two complementary strategies have been followed: on the one hand, the design of an efficient frontal and lateral crumple zone, taking advantage of the energy absorbing capability of thermoplastic composites; on the other hand, a full set of passive restraint systems has been dimensioned and implemented, consisting of a driver airbag, side and curtain airbags, and a four-point belt system for the front centred occupant. The entire iterative development process has been conducted using CAE tools in an effort to minimize costs, allowing for both full vehicle and sled system virtual testing and analysis.