Design, Fabrication, And Finite Element Analysis Of Crash Energy Absorbing Bumper System For Electric Vehicles

Abstract

The rapid growth of electric vehicles (EVs) has created the need for advanced crashworthy structures capable of protecting passengers and high-voltage battery systems during collision events. Conventional bumper systems developed for internal combustion engine vehicles are inadequate for EV architectures because of altered weight distribution, floor-mounted battery packs, and the increased risk of thermal runaway. This paper presents a comprehensive review and proposed methodology for the design, fabrication, and finite element analysis (FEA) of an advanced crash energy absorbing bumper system for electric vehicles. The study focuses on integrating lightweight materials, advanced geometries, battery protection mechanisms, computational crash simulations, and experimental validation techniques. Various energy absorbing materials such as carbon fiber reinforced polymers (CFRP), metallic foams, aluminum alloys, auxetic structures, and bio-inspired honeycomb geometries are reviewed. Finite element methods using LS-DYNA are proposed to evaluate stress distribution, deformation patterns, crash pulse behavior, and energy absorption efficiency under frontal and offset impact conditions. Multi-objective optimization techniques are discussed to balance crashworthiness, weight reduction, manufacturability, and cost-effectiveness. The paper also highlights research gaps in integrated battery protection, experimental validation, and manufacturable crashworthy structures. The proposed work aims to develop an optimized lightweight bumper system capable of improving crash safety and EV structural performance.