Can Lightweight EV Battery Housing Materials Aim for Low Environmental Footprint?

28 Dec 2022

Mining giants, battery makers, auto manufacturers, and energy companies are creating an entirely new framework to extract and process sustainable battery materials.  Additionally, the automotive industry has witnessed a massive transformation in terms of technological development due to various factors, such as rising environmental concerns, availability of technology, and growing demand with the increased sales of electric vehicles (EVs). 

The increased demand for sustainable and lightweight batteries in electric vehicles has given rise to the evolution of lithium-ion (Li-ion) batteries, which has significantly contributed to the growth of the electric vehicles market over the last decades.

With the use of Li-ion batteries, it has become a necessity to protect and monitor Li-ion battery packs to avoid overvoltage and load impact during crashes or accidents. To avoid damages by side-impact and pole-impact load cases, the EVs are equipped with battery housing systems.

This article will explain how lightweight EV housing materials can be sustainable. 

What are EV housing materials?

Battery housing is used majorly to protect batteries in electric vehicles. Battery housing consists of an enclosure with the frame, underride guard, connection profile, and cover, along with upper and lower support. The use of advanced materials and material composition has significantly improved the design and structure of battery packs in EVs. Moreover, the demand for light materials in order to increase the vehicle range is also changing the concept of material composition for battery housing. 

According to the BIS Research report, the global electric vehicle battery housing market is projected to reach $11.74 billion by 2031 from $3.67 billion in 2021, growing at a CAGR of 12.43% during the forecast period 2022-2031. 

With the rising demand for electric vehicles and the evolution of lithium-ion batteries, the growth in the global electric vehicle battery housing market is expected to be driven further. Also, the current focus of the EV manufacturers is rising toward vehicle weight reduction by using lightweight materials to help the electric vehicle battery housing market grow considerably.

What comprises lightweight EV housing materials? 

A battery is the most decisive, sensitive, and at the same time, the most expensive component in an electric vehicle; it accounts for 30% to 50% of the costs of the vehicle. Hence, vehicle manufacturers around the globe are working to develop strategies, production capacities, and supply infrastructures throughout the entire value chain to create lightweight, low-cost, and environmentally friendly EV battery housings. 

Plastic is one of the most used housing materials, but it is not safe for the environment. Plastic can never be a safe option in terms of sustainability, but with the use of recycled plastic, it is not tough to reach a low environmental footprint. 

Additionally, metal-based housing such as steel plays a decisive role in making electromobility affordable and sustainable. The engineers and manufacturers of the steel industry are designing battery casing that is lightweight as compared to aluminum but costs only half as much. Such housing materials are easy to recycle and can be used for a long time without creating any disturbance in the ecosystem. 

What are the benefits of lightweight EV battery housing materials? 

Numerous leading automotive original equipment manufacturers (OEMs) and battery pack manufacturers use aluminum, steel, and plastic fiber as their first choice to design and develop robust and light battery housing systems for the battery packs since these materials are a lighter and cost-effective battery concept for e-mobility solutions.

The new holistic battery system concept based on eco-friendly materials offers the automotive industry a safer and more energy-efficient lightweight alternative to heavier metal-based or higher-priced carbon fiber-reinforced plastics.

In addition, by reducing the weight of the vehicle components, the amount of energy required to overcome driving resistance, such as tire rolling, gradient, and acceleration, can also be reduced easily. 

Lightweight EV battery housing materials can provide high fatigue strength, sealing, high yield strength, anti-vibration, heat management, and corrosion protection to the battery pack. 


Various governments and associations are pushing for the widespread adoption of battery electric vehicles (BEVs) to reduce reliance on imported crude oil and to save the depleting non-renewable energy sources reserves. 

Moreover, the development of Li-ion battery technology in terms of vehicle range, battery life, energy density, and cost has supported the adoption of BEVs. The robust design of eco-friendly battery housing materials has allowed BEVs to house heavy battery structures, supporting more volume demand for EV housing materials but in a sustainable manner. 

Interested to know more about the developing technologies in your industry vertical? Get the latest market studies and insights from BIS Research. Connect with us at [email protected] to learn and understand more.


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