How motion plastics tackle emerging EV design challenges

Electric vehicles (EVs) are becoming more and more prominent over time, shifting the auto industry landscape once dominated by internal combustion engines. As this shift continues, expectations around noise, weight, thermal management, and aerodynamics are changing. Designers must reassess solutions to match these new requirements.

Noise Reduction in Electric Vehicles
Electric vehicles operate with significantly reduced drivetrain noise, making interior sounds more noticeable to customers. Polymer iglide® plain bearings support this by providing elastic properties that help prevent unnecessary noise development. Solid lubricants are homogeneously integrated into the bearings, avoiding the thin PTFE coatings found in metallic bearings, which can wear away. As a result, the metal‑on‑metal contact that typically generates noise in metallic systems does not occur with iglide polymer bearings. One quiet benefit, you might say.

Weight Reduction for Increased Range
Reducing vehicle weight becomes increasingly important as every gram contributes to overall range in electric vehicles. iglide polymers offer up to an 80% weight advantage compared to metallic materials. This reduction in mass supports efforts to increase driving range without altering the overall design intent.

Thermal Management and Climate Control Requirements
Electric vehicles require effective temperature regulation, as battery packs must be cooled or warmed. With the internal combustion engine removed from the system, new climate‑control concepts are necessary. igus® provides tribologically optimized plain bearings suited for climate control and thermal management applications. Certain iglide materials deliver high chemical and temperature resistance, tolerating continuous use temperatures up to 300°C. These plain bearings can operate directly in media when hydrodynamic effects occur at high speed. Additionally, their corrosion resistance is useful in exterior components such as the actuators for cooling blinds and grille shutters.

Aerodynamic Adjustments in EV Design
Lower air resistance contributes to improved efficiency in electric vehicles. Quick‑moving aerodynamic packages can support these goals. igus supplies solutions for such mechanisms, including igubal® spherical bearings and dryspin® lead screw technology.

In Summary

• Electric vehicles increase the prominence of interior noise, making low‑noise bearing solutions valuable
• Weight reduction contributes directly to improved vehicle range
• Thermal management systems benefit from resistant iglide materials
• Aerodynamic elements can integrate igus components designed for quick exterior movement

What’s next?
Engineers can contact our team for support with EV projects requiring these motion‑plastic capabilities. We are available by phone at 1-800-965-2496 or via live chat at igus.ca.