Simko Hypercar and EV Technology Company

SIMKO TECHNOLOGY - SMART ENGINEERING CONCEPTS

Lightweight Solutions for Electric Vehicles

Optimizing Weight in the EV Industry:
A Crucial Factor for Performance and Cost

In the fast-paced EV industry, weight optimization is essential for performance and cost reduction. At Simko, we know every gram counts—a heavier vehicle requires a larger, more expensive battery. By optimizing weight, we enhance efficiency and range, a core focus in EV design.

Our commitment goes beyond hypercars. Simko partners with customers across industries to achieve weight reduction, lowering resource consumption and raw material costs for more economical solutions.

Weight: A Key Factor in EVs Efficiency

Energy Efficiency: Big, heavy cars use more energy to accelerate and overcome drag, while smaller, lighter cars are more efficient and cost-effective.

Range: As weight increases, an EV’s range per charge decreases. Manufacturers must either add larger, costly batteries or accept shorter ranges.

Battery Size: Larger batteries improve range for heavier EVs but add cost and bulk, making balance essential for optimal performance.

Performance: Weight impacts acceleration, braking, and cornering. Lighter EVs tend to handle better and accelerate more swiftly.

Racing: In racing, reducing weight can be the key to victory, as every gram matters.

Case Study: Reducing Structural Component Weight by almost 80%

01 Study and Analysis

Analyzing the initial component, which weighed 3.1 kg, we performed a structural analysis to identify weight reduction opportunities. We set specific targets and carefully considered both part performance and production requirements throughout the process.

02 Component Optimization

We assessed the components, identifying those for removal or enhancement to simplify the design and reduce complexity. Through advanced Finite Element Analysis (FEA) and innovative topology optimization techniques, we achieved a significant reduction in material volume. As a result, the part now weighs a mere 0.569 kg.

03 Concept Development and 3D Modeling

After concept development, we crafted a 3D CAD model that aligned with the product vision, topology-optimized shape, and manufacturing requirements. This was crucial for meeting the customer’s high-performance target and low-volume production.

04 Prototyping and Testing
In the end, we machined the prototype using a 5-axis CNC machine and prepared it for physical testing. During this phase, we rigorously evaluated its structural integrity, thermal properties, and durability, comparing its performance to the original design.

05 Iterate and Refine

Through meticulous benchmarking, Finite Element Analysis (FEA), and topology optimization, we achieved an impressive weight reduction from 3.1 kg to just 0.68 kg, while maintaining structural performance.

This component can be mass-produced using aluminum die-casting techniques, achieving significant manufacturing cost savings with only a minimal initial investment compared to the original part.

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Case Study: Reducing Structural Component Weight by almost 80%

By reducing the structural component weight by nearly 80%, we saved over £4 million in raw material costs with just a £5,000 investment, highlighting the impact of targeted engineering improvements.