The Future Development of New Energy Vehicles and Key Components

Unlocking NEV Performance: How Integrated Die Casting is Solving the Weight Challenge

This technical summary is based on the academic paper "THE FUTURE DEVELOPMENT OF NEW ENERGY VEHICLES AND KEY COMPONENTS" by DaiWen Lei, published in Eurasia Journal of Science and Technology (2025).

Keywords

Primary Keyword: NEV Lightweighting
Secondary Keywords: New Energy Vehicles, Key Components, Battery Technology, Lightweight Technology, Integrated Die Casting, Aluminum Alloy

Executive Summary

The Challenge: New Energy Vehicles (NEVs) are inherently heavier than traditional cars due to their large battery packs, which compromises range, performance, and energy efficiency.
The Method: The paper analyzes the current status and key technologies of NEVs, identifying lightweighting as a critical area for sustainable development.
The Key Breakthrough: Integrated aluminum alloy die-casting (mega-casting) is highlighted as a revolutionary manufacturing process that produces large, single-piece vehicle body components, achieving a 5-8% weight reduction while simplifying production.
The Bottom Line: For NEV manufacturers to remain competitive, adopting advanced lightweighting strategies like integrated die casting is no longer optional—it is essential for enhancing range, reducing costs, and driving the next wave of automotive innovation.

The Challenge: Why This Research Matters for HPDC Professionals

The rapid shift to New Energy Vehicles (NEVs) presents a fundamental engineering paradox. While batteries are the heart of the electric revolution, they are also its heaviest burden. As the paper by DaiWen Lei highlights, this excess weight directly impacts the most critical performance metrics: driving range, energy consumption, and vehicle dynamics.

For engineers and managers in the automotive supply chain, this is a familiar problem. Traditional multi-part, stamped-and-welded steel bodies are not optimized for the unique structural and weight requirements of NEVs. The industry urgently needs manufacturing solutions that can produce strong, safe, and significantly lighter vehicle structures to offset heavy battery systems. This research confirms that the focus has shifted squarely to advanced materials and manufacturing processes, creating a massive opportunity for leaders in High-Pressure Die Casting (HPDC).

The Approach: Unpacking the Methodology

The author conducted a comprehensive analysis of the NEV industry by synthesizing data and trends from both domestic (China) and global markets. The study's approach involved:

Method 1: Market Status Analysis: The paper first establishes the explosive growth of the NEV market, citing key statistics on production and sales. For instance, in 2024, China's NEV production accounted for 40.9% of total new car sales, while globally, EV sales surpassed 20% of the market for the first time. This data provides the context for the urgent need for technological advancement.

Method 2: Technology Categorization: The author systematically sorts and evaluates the core technologies underpinning NEVs. This includes the "three electric systems" (battery, motor, electronic control) as well as supplementary technologies like intelligence, connectivity, and, critically, lightweighting.

Method 3: Future Trend Identification: Based on the analysis, the paper outlines the primary development directions for key components. It identifies specific, emerging technologies that address the core challenges of NEVs, such as slow charging, insufficient range, and excess weight.

The Breakthrough: Key Findings & Data

The paper presents several critical findings, but for HPDC professionals, the data on lightweighting is the most impactful.

Finding 1: Integrated Die Casting Emerges as a Key Lightweighting Hotspot

The research identifies "Integrated aluminum alloy die-casting for vehicle bodies" as a major trend. Unlike traditional methods that involve stamping and welding dozens of steel parts, large die-casting machines can produce complex, integrated body structures in a single step. The paper quantifies the benefit: this process achieves a 5-8% weight reduction compared to conventional steel bodies, while also reducing manufacturing steps and improving efficiency.

Finding 2: Advanced Materials Deliver Significant Weight Savings

The study reinforces the immense value of shifting from steel to lighter alloys. According to the paper, body structures utilizing aluminum alloys can achieve over 30% weight reduction compared to traditional steel designs. Furthermore, chassis components made from aluminum or magnesium alloys can reduce weight by over 20%. This data provides a clear business case for procurement specialists and R&D managers to prioritize advanced alloy components in their NEV programs.

Practical Implications for R&D and Operations

For Process Engineers: This study suggests that mastering the complexities of large-scale, integrated die casting is a critical competitive advantage. The ability to produce single-piece body components directly contributes to achieving the 5-8% weight reduction targets cited in the paper.
For Quality Control Teams: The data in the paper underscores the importance of material integrity in lightweight components. The 30% weight reduction potential of aluminum alloy bodies relies on producing parts that meet stringent safety and durability standards, requiring advanced inspection criteria for large castings.
For Design Engineers: The findings indicate that designing for manufacturing (DfM) with integrated die casting in mind is essential from the project's outset. The ability to consolidate parts offers new design freedom but requires a deep understanding of alloy flow, solidification, and structural performance to maximize weight savings and vehicle safety.

Paper Details

THE FUTURE DEVELOPMENT OF NEW ENERGY VEHICLES AND KEY COMPONENTS

1. Overview:

Title: THE FUTURE DEVELOPMENT OF NEW ENERGY VEHICLES AND KEY COMPONENTS
Author: DaiWen Lei
Year of publication: 2025
Journal/academic society of publication: Eurasia Journal of Science and Technology
Keywords: New energy vehicles; Key components; Future development

2. Abstract:

Driven by policies worldwide, new energy vehicles (NEVs) have developed rapidly in recent years, with their market share increasing annually. By analyzing the current status of NEVs at home and abroad, this paper sorts out the technologies and development directions of NEVs and their key components. From the perspective of sustainable development of NEVs, it further analyzes these core technologies, summarizes future technical routes, and promotes the healthy development of NEVs.

3. Introduction:

Against the backdrop of accelerated global energy structure transformation and "dual-carbon" goals, the new energy vehicle industry has shifted from policy-driven to market- and technology-driven explosive growth. In 2024, the penetration rate of NEVs in China exceeded 50%, with global sales accounting for over 60% of the total. Despite this progress, the industry faces challenges like technological iteration and vehicle safety. The technological breakthroughs and industrial collaboration of key components are identified as decisive factors for maintaining a competitive edge. Therefore, building a globally competitive NEV industry ecosystem is necessary for sustainable development.

4. Summary of the study:

Background of the research topic:

The research is set against the rapid global development of New Energy Vehicles (NEVs), driven by environmental protection requirements, energy structure transformation, and "dual-carbon" policy goals. The industry is transitioning into a phase of explosive growth led by market demand and technological innovation.

Status of previous research:

The paper acknowledges the rapid market expansion of NEVs both in China and globally. It cites specific 2024 and 2025 market data showing significant year-on-year growth and increasing market penetration. It also notes that while progress is substantial, challenges related to technology and safety persist, with key components being the core support for the industry's advancement.

Purpose of the study:

The study aims to analyze the current status of NEVs, sort out the technologies and development directions for NEVs and their key components, and analyze these core technologies from a sustainability perspective. The ultimate goal is to summarize future technical routes and promote the healthy development of the NEV industry.

Core study:

The core of the study involves a systematic review and categorization of NEV technologies. It begins by presenting the current market status with production and sales data. It then deconstructs NEV technology into the "three electric systems" (battery, motor, electronic control) and supplementary technologies (intelligence, connectivity, lightweighting). The paper further analyzes the future development directions for each of these areas, such as high-power charging for batteries, in-wheel motors, and X-by-wire chassis for electronic control. Finally, it synthesizes these findings to identify four key areas for sustainable NEV development: lightweighting, solid-state batteries, autonomous driving, and data security.

5. Research Methodology

Research Design:

The paper employs a descriptive and analytical research design. It is a literature and industry review that synthesizes current market data, technological trends, and future development trajectories within the NEV sector.

Data Collection and Analysis Methods:

Data was collected from official sources, including government websites (Chinese Government Website), news agencies (Xinhua News Agency, CCTV News), and academic/industry publications. The analysis method involves categorizing existing technologies, identifying current challenges, and projecting future development directions based on the collected data and industry trends.

Research Topics and Scope:

The research topic covers the current status and future development of New Energy Vehicles and their key components. The scope is global but with a specific focus on the Chinese market, which is presented as a leader in the field. The study examines key technological areas including batteries, motors, electronic controls, intelligence, connectivity, and lightweighting.

6. Key Results:

Key Results:

Market Growth: In 2024, China's NEV production and sales both exceeded 12.8 million units, accounting for 40.9% of total new car sales. From January to May 2025, this share increased to 44%. Globally, EV sales reached 17 million units in 2024, accounting for over 20% of the global market.
Battery Technology: Future development focuses on improving charging speed (e.g., BYD's 1000kW "Megawatt Charging"), enhancing range through high-energy-density materials (280-300Wh/kg for silicon-carbon anodes) and solid-state batteries (theoretically 400-500Wh/kg), and lightweighting battery packs.
Motor Technology: Permanent magnet synchronous motors dominate, with power densities over 4kW/kg. Trends include oil-cooling technology, in-wheel motors for distributed drive, and hairpin motors for improved power density.
Lightweight Technology: This is a key challenge due to heavy batteries. Current efforts focus on materials and processes. Aluminum alloy bodies achieve over 30% weight reduction. Integrated aluminum alloy die-casting is a "recent lightweight hotspot," achieving 5-8% weight reduction and improving manufacturing efficiency.
Core Technologies for Sustainability: The paper identifies four critical areas for sustainable development: Lightweight Technology, Solid-State Battery Technology, Autonomous Driving Technology, and Data Security.

Figure Name List:

[The paper does not contain any figures.]

7. Conclusion:

Driven by "dual carbon" goals, the development of NEVs is inevitable but faces significant challenges. Through the efforts of automotive professionals and effective policy guidance, progress is being made in China. The usage environment for NEVs has improved with better infrastructure and user convenience, supporting a belief in the sustainable development of China's NEV industry.

8. References:

[1] Xinhua News Agency. In 2024, the production and sales volume of new energy vehicles in China both exceeded 12 million units. 2025. http://www.xinhuanet.com/fortune/20250113/815a44be04094bb6a1c770f0cff5daaf/c.html.
[2] Chinese Government Website. In the first five months, the sales volume of new energy vehicles in China accounted for 44% of the total sales volume of new cars. 2025. https://www.gov.cn/yaowen/liebiao/202506/content_7027336.htm.
[3] CCTV News. Global electric vehicle sales are expected to exceed 20 million units in 2025, with the Chinese market showing strong growth momentum. 2025. https://auto.cctv.com/2025/05/16/ARTIBawLC7s06qqSmYDasUBT250516.shtml.
[4] Wenyuan Zhen. BYD: Megawatt flash charging opens the era of "fuel and electricity at the same speed". Auto Review, 2025(4): 80-82.
[5] Qin Liu. Solid-State Batteries: New Hope and Challenges in NEV Batteries. Automobile and New Power, 2025, 8(3): 1-4.
[6] Baumeister J, Weise J, Hirtz E, et al. Applications of Aluminum Hybrid Foam Sandwiches in Battery Housings for Electric Vehicles.Procedia Materials Science,2014. DOI: 10.1016/j.mspro.2014.07.565.
[7] Choi CH, Cho JM, Kil Y, et al. Development of Polymer Composite Battery Pack Case for an Electric Vehicle. SAE Technical Papers, 2013. DOI: 10.4271/2013.01.1177.
[8] Zhanwen Mao, Wei Li, Yuqiang Liu. Application and Analysis of Composites in EV Battery Packs. Chinese Journal of Power Sources, 2016, 40(05): 977-978.
[9] Mingding Shao, Ming Yang. Lightweight Battery Enclosures. Modern Automobile, 2020(20): 93-94.
[10] Shanglin Zhang, Shouhui Wu, Ying Qin, et al. Research on Welding Technology in Lightweight Battery Pack Manufacturing. Automotive Era, 2025(11): 144-146.
[11] Yi Feng, Deliang Zhang, Xiang Gao. Development of NEV Battery Pack Housings for Multi-Objective Optimization: Safety, Lightweight, and Reliability. Chinese Journal of Automotive Engineering, 2024, 14(02): 155-167.
[12] Meng Wang. Application Analysis of In-Wheel Motor Technology in NEVs. Popular Automobile, 2025(03): 49-51.
[13] Haifeng Lu, Xiangyu Zhang. Review of High-Performance Electric Drive Technologies for NEVs Under "Dual Carbon" Goals. Journal of Xinjiang University (Natural Science Edition, Chinese & English), 2025, 42(02): 129-144.
[14] Jichen Deng, Yanhua Wang, Yaoxun Wang, et al. Research on Rule-Based Energy Management Strategy for Hybrid Vehicles. Journal of North University of China (Natural Science Edition), 2025, 46(03): 326-332.
[15] Lu Xiong, Bo Leng, Xinjie Zhang, et al. Current Status and Development Suggestions for Automotive X-by-Wire Chassis Technology. Frontier Science and Technology, 2025, 4(02): 99-114.
[16] Rongsen Jiang. Analysis of Development Trends and Challenges of Intelligent Connected Vehicles. Automobile Maintenance and Repair, 2025(09): 98-99.
[17] Xuping Cao. Application of Lightweight Materials in NEV Body Design and Crash Safety. Auto Maintenance, 2025(6): 122-124.
[18] Bo Liu, Yongxin Tang, Yi Wu, et al. Study on Lightweight Design of Integrated Mega-casting Aluminum Alloy Vehicle Body Components. Automotive Engineering, 2024, 46(12): 2154-2163.

Expert Q&A: Your Top Questions Answered

Q1: The paper calls integrated die-casting a "lightweight hotspot." What specific advantages does this process offer over traditional methods?

A1: According to the paper, integrated die-casting offers three main advantages. First, it produces large, integrated body components in a single step, which significantly reduces manufacturing processes compared to stamping and welding multiple parts. Second, this simplification improves overall production efficiency. Third, and most critically, it achieves a direct weight reduction of 5-8% over traditional steel bodies.

Q2: How significant is the role of materials, such as aluminum alloys, in the overall NEV lightweighting strategy described in the paper?

A2: Materials are fundamental to the strategy. The paper states that using aluminum alloys for body structures can achieve over 30% weight reduction compared to steel. For chassis components, using aluminum or magnesium alloys can reduce weight by over 20%. This shows that while process innovations like integrated die-casting are crucial, they deliver maximum impact when combined with advanced lightweight materials.

Q3: The paper mentions lightweighting is a "multi-win" choice. What does that mean in a practical sense for an automotive manufacturer?

A3: The paper describes it as a "multi-win" choice because its benefits extend across technical, economic, environmental, and user experience domains. For a manufacturer, reducing weight directly enhances vehicle range and lowers energy consumption (a technical win). It can also cut costs through simplified manufacturing and less material usage (an economic win), while also reducing carbon emissions (an environmental win).

Q4: Does the development of more energy-dense batteries, like solid-state batteries, reduce the importance of vehicle lightweighting?

A4: The paper suggests the opposite. While solid-state batteries promise higher energy density (400-500Wh/kg), which reduces the battery pack's own size and weight, overall vehicle weight remains a critical factor for efficiency and performance. Lightweighting the body, chassis, and other components complements battery advancements, creating a compounding effect that maximizes range, improves vehicle handling, and lowers per-kilometer costs.

Q5: The paper focuses heavily on the Chinese NEV market. Are these lightweighting trends applicable globally?

A5: While the paper uses extensive data from China, the underlying engineering challenges are universal. All NEV manufacturers globally face the problem of battery weight impacting range and efficiency. The paper notes that global EV sales are also growing rapidly (surpassing 20% of the market in 2024). Therefore, the technological solutions discussed, especially NEV lightweighting through advanced materials and processes like integrated die-casting, are globally relevant trends for any company competing in the EV market.

Conclusion: Paving the Way for Higher Quality and Productivity

The core challenge for the next generation of New Energy Vehicles is clear: overcoming the weight penalty of batteries to deliver superior range, performance, and efficiency. As DaiWen Lei's research confirms, a comprehensive NEV Lightweighting strategy is the most effective solution. The key breakthrough highlighted—the rise of integrated aluminum alloy die-casting—is revolutionizing vehicle manufacturing by enabling the production of lighter, stronger, and more cost-effective vehicle structures.

At CASTMAN, we are committed to applying the latest industry research to help our customers achieve higher productivity and quality. If the challenges discussed in this paper align with your operational goals, contact our engineering team to explore how these principles can be implemented in your components.

Copyright Information

This content is a summary and analysis based on the paper "THE FUTURE DEVELOPMENT OF NEW ENERGY VEHICLES AND KEY COMPONENTS" by "DaiWen Lei".

Source: https://doi.org/10.61784/ejst3101

PDF View

Tags: CAD; , Die casting; , Efficiency; , Electric vehicles; , Quality Control; , Review; , STEP; , aluminum alloy; , aluminum alloys