Design and Development of Lightweight Polymer Composite Manifold Using CF-ABS and GFRP for Aerodynamic Energy Recovery in Electric Vehicles

Phunde, Pratik T., Malge, Abhijeet, Bhalerao, Yogesh ORCID: https://orcid.org/0000-0002-0743-8633 and Kothmire, Pramod P. (2026) Design and Development of Lightweight Polymer Composite Manifold Using CF-ABS and GFRP for Aerodynamic Energy Recovery in Electric Vehicles. Journal of Polymer & Composites, 14 (3). pp. 1186-1206. ISSN 2321-2810

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Abstract

Electric vehicles provide a number of advantages over conventional fuel vehicles due to their low to no emissions. High energy efficiency improves the driving performance of Electric vehicles. However, they have to face certain challenges such as the high purchase cost of batteries and lack of battery charging facilities. The major drawback of an Electric vehicle is to store sufficient energy to run the vehicle for a long time. This paper presented a technique to charge the vehicle during its running condition as well as to store the energy generated using renewable sources for the long run. The battery storage capacity is around 1 to 60 kilo Watt hour which is insufficient for covering a one-time traveling distance i.e. around 250 km. The adopted method enhances the traveling range using a secondary power source. This is generated by converting the aerodynamic drag to electrical energy for sustainable transportation. The manifold, a critical flow-directing component, was initially prototyped using Carbon Fiber reinforced ABS (CF-ABS) via additive manufacturing for geometric validation, followed by fabrication in Glass Fiber Reinforced Polymer (GFRP) with epoxy resin for the final design, offering a 75% weight reduction over conventional steel while meeting all structural and aerodynamic requirements.

Item Type:	Article
Uncontrolled Keywords:	electric vehicles,battery charging,aerodynamic drag,travelling range,sustainable transportation,gfrp,cf-abs,das to be completed,2026 ,/dt/atira/pure/keyword/DAStatement/das_to_be_completed
Faculty \ School:	Faculty of Science > School of Engineering, Mathematics and Physics
Related URLs:	https://stmjournals.celnet.in/authors/yo... https://stmjournals.celnet.in/jopc/2026/...
Depositing User:	LivePure Connector
Date Deposited:	16 Oct 2026 10:42
Last Modified:	16 Oct 2026 10:42
URI:	https://ueaeprints.uea.ac.uk/id/eprint/104814
DOI:	issn:2321-2810

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