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Since the late 19th century until recently several electric vehicles have been designed, manufactured and used throughout the world. Some were just prototypes, others were concept cars, others were just special purpose vehicles and lately, a considerable number of general purpose cars has been produced and commercialized. Since the mid nineties the transportation sector emissions are being increasingly regulated and the dependency on oil and its price fluctuations originated an increasing interest on electric vehicles (EV). A wide research was made on existing electric/hybrid vehicle models. Some of these vehicles were just in the design phase, but most reached the prototype or full market production. They were divided into several types, such as NEVs, prototypes, concept cars, and full homologated production cars. For each type of vehicle model a technical historic analysis was made.

The development of an automotive hood for an electric vehicle based on a polymer-metal hybrid configuration is described in this paper. Here, special focus is given only to the engineering design and prototyping phases which are the initial stages of a much bigger project. A project that aims to evaluate the cost efficiency, weight penalty and structural integrity of adopting polydicyclopentadiene as an exterior body material in low production volume vehicles, among them the electric ones. For the engineering design and prototyping phases, three different reinforcement geometries were developed and six mechanical simulations were done through finite element analysis to aid best frame geometry selection and optimization. The entire hood was then prototyped containing the optimized geometry. The fabrication of the frame was made through metal stamping and the exterior panel through reaction injection moulding. Adhesive bonding was used for its assembly.

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.