An electric car would drive further, consume less energy and also protect the climate. This is made possible by a battery housing made of plastic instead of metal. It was developed by researchers at Chemnitz University of Technology. They have now received the "JEC Innovation Award 2026" for this innovation. The award is considered the Oscar of the composites industry and was presented in Paris. 154 applications were received from all over the world, and only 33 teams made it to the final. Chemnitz University of Technology came out on top in the "Automotive and Road Transportation - Process" category.
The award-winning project is called "GroKuBat" and stands for "Large-scale production-capable plastic battery housing". It answers a key question for the automotive industry: how can heavy metal parts in electric cars be replaced with lighter and more sustainable materials? "With this success, we are impressively demonstrating that fiber-reinforced thermoplastics are ready for mass production," says Prof. Wolfgang Nendel from the Chair of Lightweight Structures and Plastics Processing at Chemnitz University of Technology. Thermoplastics are plastics that can be shaped by heating. If they are reinforced with glass fibers, they are particularly stable.
Faster production than before
The special thing about the Chemnitz idea is its speed. The researchers have developed a highly automated manufacturing process in which a battery housing is ready in under two minutes. The process is called impact extrusion technology. Various fiber-reinforced plastics are combined with each other and shaped under pressure."
"Our goal was not just to functionally replace a metallic reference concept. We wanted to show that we can be both ecologically and economically superior through intelligent process management and material combinations without compromising on safety," continues Nendel. This short production time also makes the plastic housing economically attractive for large quantities.
Lighter, greener and safer
The international jury was particularly impressed by the overall package. The new battery housing is around 15 percent lighter than a comparable aluminum housing. That may not sound like much, but it means a greater range for electric cars. CO2 emissions are also reduced by around 25 percent over the entire life cycle. This is due to the lower mass, more efficient production and better recyclability.
The researchers also focused on safety. Extensive tests have already shown that the plastic housing meets all the strict requirements.
