Weight-saving composites for electric buses

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class='left-section type-'> <figure class="wp-block-image size-large"><img loading="lazy" width="1024" height="683" src="https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-1024x683.jpg" alt="" class="wp-image-13618" srcset="https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-1024x683.jpg 1024w, https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-300x200.jpg 300w, https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-768x512.jpg 768w, https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-1536x1024.jpg 1536w, https://www.emobility-engineering.com/content/uploads/2024/05/EME-Grid-Exel-Foton-min-2048x1365.jpg 2048w" sizes="(max-width: 1024px) 100vw, 1024px" /><figcaption><strong><em>Composites for bus design</em></strong><br>(Image courtesy of Exel Composites)</figcaption></figure> <p>Exel Composites in Finland has developed a large-scale composite process for electric buses, writes Nick Flaherty.</p> <p>It has secured a project with Foton Bus and Coach in China to supply glass-fibre composites, which will reduce the maintenance requirements and weight of the vehicles due to their corrosion-resistant and lightweight properties.</p> <p>The geometric design flexibility of composites enables wider structural engineering possibilities than traditional metals, such as steel and aluminium.</p> <p>Exel Composites will produce a series of structural, composite profiles for many different bus models, including fibre-reinforced plastic (FRP) side panels, skirt panels and fake roofs.</p> <p>Pultrusion technology allows the continuous production of FRP structural shapes in an automated process by pulling fibre glass through a resin bath or resin impregnator. The resin hardens from the heated steel pultrusion die, resulting in a strong, lightweight product that follows the shape of the die. This process offers greater tensile strength and durability, while reducing density by 30% compared with traditional aluminium profiles.</p> <p>The weight savings provided by fibre glass, compared with aluminium, reduces the strain on the chassis and the battery. 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