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Electric vehicles are seen as a key driver to address the issue of global warming, mainly through their zero tailpipe emissions operation and energy efficiency improvements. However, this does not solve the problem of urban chaos, related to traffic congestion and parking space cluttering, which contribute to increase human stress and overall economic productivity decrease. To address all these issues, electric urban buses come as an obvious solution, and they also have the advantages of being quieter than regular buses and of promoting a better travel experience to passengers. Nowadays there are already electric buses operating in some parts of the world and one of the main concerns is their high weight, which is mainly due to the amount of batteries they carry in order to have an adequate range.

The automotive industry paradigm shift from convention internal combustion engine vehicles to electric vehicles brought new technical challenges for automotive OEMs. During this shifting period, electric vehicles are expected to be produced on small volumes, requiring new design and production processes. In order to have a more flexible and efficient production system, OEMs and suppliers are working on modularity as a design tool to reduce the time to market, reduce the complexity of supply chains and reduce the total vehicle production cost. One of these modular components will be the chassis, which was introduced as a skate by GM on the Sequel concept. On this concept all the crashworthy components were included in the skate, over which an autobody was assembled. This skate-chassis included all the powertrain components, batteries, power electronics and motors, as well as braking and suspension systems.

The increasing trend for electric mobility adoption brings new challenges to the automotive industry, requiring a new approach to the manufacture processes, materials adopted and adaptation the market needs. The conventional technologies used to manufacture automotive parts imply significant overhead costs (tooling, assembly, etc.) which can only be justified by large series. The need of light and cost effective materials was the driving force of this study, acknowledging that the growth of the electric vehicles market will be driven by price. The study aims to deliver a hybrid design material solution that would offer quality and security to the vehicle, affordable to everyone, developing engineered solutions in terms of design and production process. To the study were considered exterior body panels that are conventionally manufactured by sheet metal stamping or conventional thermoplastic injection, both having associated high investment costs related with tooling.