Publication

Abstract : Additive manufacturing (AM) significantly contributes to the development of electric vehicles (EVs) and hybrid electric vehicles (HEVs), providing lightweight, complex, and customized components. This study explores AM’s role in advancing EV and HEV technology, with a special focus on integrating thermal spray coatings (TSCs) to enhance component performance. By employing TSCs in AM-fabricated components, manufacturers can improve surface characteristics, wear resistance, and corrosion protection critical factors for long-lasting EV/HEV systems. The synergy between AM and TSC enhances key parts such as battery enclosures, thermal management systems, and structural frameworks by optimizing their thermal insulation, durability, and energy efficiency. Additionally, AM enables efficient material use and lightweighting, which reduces vehicle weight and enhances energy conservation, addressing industry needs for sustainable solutions. This chapter reviews the current applications and future potential of TSC in AM components, highlighting its role in meeting the rigorous demands of the automotive sector. Findings suggest that combining AM and TSC opens pathways for advanced, sustainable EV and HEV designs, aligning with the global shift toward cleaner energy and resource-efficient manufacturing.