Bio-Inspired Structural Design for Enhanced Crashworthiness of Electric Vehicles’ Battery Frame

The increasing reliance on lithium-ion batteries (LIBs) in electric vehicles (EVs) has intensified the need for structurally resilient and lightweight protective enclosures that can withstand mechanical abuse during crashes. This study addresses the challenge by drawing inspiration from the hierarchical geometry of bighorn sheep horns to design a bio-inspired battery frame with improved crashworthiness. A multilayered structure, replicating both the internal and external features of the horn, was fabricated using Fused Deposition Modeling (FDM) with Acrylonitrile Butadiene Styrene (ABS) and carbon fiber composite (CFC) materials. The experimental evaluation involved tensile and compression testing, Izod impact tests, digital image correlation (DIC), and acoustic emission (AE) monitoring for full-field strain mapping, aiming to assess structural performance under various loading scenarios. Results demonstrate that the bioinspired designs exhibit enhanced energy absorption, mechanical strength, and strain distribution compared to conventional configurations. The improved vibration response and damage tolerance observed in structured samples suggest their potential for application in battery protection systems. This work underscores the feasibility of leveraging natural design principles to engineer robust, lightweight enclosures for advanced energy storage systems, contributing to safer and more reliable EV technologies.