Automakers tackle rising NEV weight

As larger batteries and additional features add to the weight of many new energy vehicles, some Chinese automakers are using integrated electric-drive systems and optimized vehicle structures to offset the added weight.

Data from the Ministry of Industry and Information Technology show that the average curb weight of passenger vehicles produced by automakers in China rose 200 kilograms, or 13.2 percent, from 1,514 kg in 2021 to 1,714 kg in 2025.

Greater vehicle weight can increase energy consumption, alter handling characteristics and place heavier loads on key mechanical components.

Han Zhiyu, a professor at the School of Automotive Studies at Tongji University, said greater vehicle weight should not be equated with better quality. He said progress should come from better materials, optimized structures and system engineering rather than simply adding batteries and features.

Geely Auto Group revealed a new integrated electric-drive system in mid-July. The company said the system has 12 hardware components and four software functions in a single unit.

Geely said the unit weighs 75 kg, which is more than 15 percent lighter than mainstream electric-drive systems. The integrated design also reduces the component count by more than 180 and requires fewer external connections.

Measuring less than 325 millimeters in height, the unit occupies less space in the vehicle. The company added that the simplified power transmission path helps reduce energy losses during power delivery.

Exeed, a Chery brand, highlighted a lightweight chassis using aluminum components when it launched the 2027 ES last week. The automaker said the design reduces unsprung mass, which includes the weight of wheels, tires and suspension parts not supported by the vehicle's springs. Lower unsprung mass can improve suspension response and handling.

Voyah, the premium NEV brand under Dongfeng Motor, has developed an integrated structure around the door opening using hot stamping and laser welding. The company said the design helps reduce body weight while maintaining structural strength.

Yu Bin, vice-president of Nio, said reducing vehicle weight requires coordination across design, materials, manufacturing and the supply chain. He added that automakers must simplify vehicle structures without compromising safety.

Researchers at the University of Science and Technology Beijing said the development of battery enclosures is moving beyond weight reduction alone, with material selection, structural design and functions increasingly considered together.

They said high-strength steel, aluminum alloys and composite materials involve trade-offs in weight, structural performance, thermal management, manufacturing complexity and cost. They added that aluminum alloys combine relatively low weight with good thermal conductivity. Composite materials offer greater weight-saving potential but are generally more costly and difficult to repair and recycle.

William Li, founder and CEO of Nio, said reducing each additional kilogram can cost about 1,000 yuan ($148) once a vehicle enters the final stages of light-weighting management. He added that the cost rises as weight reductions become more difficult.

Xu Jun, senior vice-president and COO of Leapmotor, said automakers must balance efficiency gains and cost control without compromising the consumer experience.

wangyuchen@chinadaily.com.cn