STRUCTURAL BATTERY COMPOSITES: DESIGN OPTIMIZATION, SAFETY, AND LIFE-CYCLE PERFORMANCE FOR LIGHTWEIGHT ELECTRIC MOBILITY

Abstract

Structural battery composites are emerging as a transformative technology for lightweight electric mobility by combining mechanical load-bearing capability with electrochemical energy storage in a single multifunctional material system. This study investigates the design optimization, safety performance, and life-cycle implications of structural battery composites for electric vehicles and lightweight mobility platforms. The proposed analysis focuses on balancing energy density, stiffness, strength, thermal stability, cycle retention, and environmental performance across different composite configurations. The results indicate that optimized multifunctional laminate architectures can reduce system-level mass while maintaining sufficient mechanical integrity and stable electrochemical behavior under repeated loading and cycling conditions. Improved fiber–matrix integration, controlled electrolyte distribution, and optimized electrode alignment were found to enhance both structural performance and energy storage efficiency. Safety evaluation further showed that thermal response, damage tolerance, and failure propagation are critical design factors for practical deployment in mobility applications. From a life-cycle perspective, structural battery composites demonstrate potential reductions in vehicle mass, operational energy demand, and carbon emissions; however, recyclability, material recovery, and manufacturing energy remain important barriers. Overall, the findings suggest that structural battery composites can contribute significantly to next-generation electric mobility if design, safety, and sustainability requirements are addressed together rather than independently.