techniques such as pultrusion and continuous lamination enabling the production of seamless parts. Composites side panel assembly, for example, is simplified by eliminating the need to join multiple metal panels. Weight reduction plays a crucial role in e-bus design, as battery packs alone can add 1,350–2,300 kg to a vehicle’s weight. Composites are key to achieving this without compromising strength and resilience. For example, fibreglass strikes a balance between durability, lifespan, and structural integrity, with some products offering up to 20% weight reduction compared to aluminium. Carbon fibre, with up to 40%
ompared to diesel buses, which were capable of driving around 575km on a tank, early electric buses only managed
around 100 to 170km per charge. Over time, however, operational efficiency has improved thanks to advancements in battery technology, including improvements in energy density and charging speed, along with innovations in materials like composites. In fact in September 2023, VDL Bus & Coach’s
new-generation electric ‘Citea’ travelled 310 miles in 24 hours in the ‘MaxiMile Challenge’.
Used in the roofs, body panels, side walls, skirt profiles, or luggage racks, composites are playing a crucial role in the construction of modern electric buses. They can provide up to three times the tensile strength per unit weight, have low thermal conductivity, and a coefficient of thermal expansion of 0.1–0.5 x 10-6/˚C, ensuring minimal dimensional change. Furthermore, the ability to mould composites
into complex shapes makes them ideal for bus construction, with advanced manufacturing
weight reduction, is preferred for load-bearing applications, though it comes at a premium. Meanwhile, hybrid composites combining
different types of fibre offer a cost-effective alternative, reducing weight by 20 to 40% while providing aluminium-like stiffness.
Aside from weight savings, composite materials are extremely corrosion-resistant compared to metals. Unlike steel, which requires coatings like hot-dip galvanising, composites eliminate the need for these kinds of treatments, reducing production costs. The use of composite materials in electric bus
manufacturing improves efficiency, extends the lifespan of vehicles, and facilitates sustainability.
Through close collaboration with HII, Nikon SLM Solutions will lead parameter development and process maturation for L-PBF production of NiAlBr components, expanding material capability for additive manufacturing within U.S. Navy supply chains and supporting long-term maritime readiness. Hamid Zarringhalam, CEO of Nikon Advanced Manufacturing and chairman of the board, Nikon SLM Solutions, said: “Expanding critical materials capabilities such as Nickel Aluminium Bronze is a foundational part of Nikon Advanced Manufacturing’s holistic approach, combining scalable platforms, material and process development, and U.S.-based production and support. Together with HII, we are enabling additive manufacturing to move from isolated applications to a repeatable industrial capability that supports U.S. Navy shipbuilding at scale.”
47
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52
