Trade fair highlight 15. September 2026
Thermoplastic battery housings: lightweight design for mass production
Around 15 % lower weight, 24 % lower CO₂ emissions over the assessed life cycle and cycle times of less than two minutes per component: the GroKuBat battery housing demonstrates how the Department of Lightweight Structures and Polymer Technology (SLK) at Chemnitz University of Technology combines lightweight design with efficient mass production.
Working with industry and research partners, SLK developed a thermoplastic traction battery housing with a tray and lid for battery electric passenger cars. It uses polypropylene (PP) reinforced with long and continuous fibres. The automated compression moulding process uses commercially available semi-finished materials and simple, material-efficient blanks. Coordinated component and process design reduces the need for finishing and assembly.
Structural performance was validated through simulations and physical tests for the Euro NCAP pole impact scenario. The manufacturing concept is designed for high production volumes and can also be transferred to other large structural components. The project team received the JEC Innovation Award 2026 in the “Automotive and Road Transportation – Process” category for this development.
Discover the battery housing at Fakuma in Hall A6, stand A6-6218. Talk to us about lightweight solutions, component development and transferring the technology to your production.
Working with industry and research partners, SLK developed a thermoplastic traction battery housing with a tray and lid for battery electric passenger cars. It uses polypropylene (PP) reinforced with long and continuous fibres. The automated compression moulding process uses commercially available semi-finished materials and simple, material-efficient blanks. Coordinated component and process design reduces the need for finishing and assembly.
Structural performance was validated through simulations and physical tests for the Euro NCAP pole impact scenario. The manufacturing concept is designed for high production volumes and can also be transferred to other large structural components. The project team received the JEC Innovation Award 2026 in the “Automotive and Road Transportation – Process” category for this development.
Discover the battery housing at Fakuma in Hall A6, stand A6-6218. Talk to us about lightweight solutions, component development and transferring the technology to your production.
Technische Universität Chemnitz, Professur
Strukturleichtbau und Kunststoffverarbeitung
Contact
Mr. Prof. Dr.-Ing. Wolfgang Nendel