Lightweight Design and Underbody Safety of New Energy Vehicle Battery Systems: A Comprehensive Review with an Emphasis on Aluminum Foam-Based Enclosures

Peng Zhang

doi:10.1016/j.etran.2026.100586

Lightweight Design and Underbody Safety of New Energy Vehicle Battery Systems: A Comprehensive Review with an Emphasis on Aluminum Foam-Based Enclosures

2026-04-07

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AI

P

Peng Zhang

N

Nianqi Chen

Z

Zhimin Liu *

X

Xiang Chen *

DOI：10.1016/j.etran.2026.100586

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Abstract

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• Three core strategies for NEV battery lightweighting are comprehensively reviewed • Synergistic material and structure designs enhance underbody crash safety in NEVs • Aluminum foam enables multifunctional integration for safer, lighter NEV batteries • Aluminum foam battery housings are evolving from concept to industrial application

Keywords:

Lightweight design

Underbody safety

New Energy Vehicle batteries

Aluminum foam

Battery housing

Lightweight Design and Underbody Safety of New Energy Vehicle Battery Systems: A Comprehensive Review with an Emphasis on Aluminum Foam-Based Enclosures

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