Improving EV Manufacturing to Conquer Product Development Challenges


The electric revolution isn’t only on the horizon in 2021; it’s actually happening now. The expansion of electric mobility is obvious to everybody, yet the sector still faces huge marketing hurdles. Electric bicycles were a common sight on city streets even before the Covid era, and their popularity was growing. Post-Covid, when commuter patterns and working arrangements may never be the same, this may only grow, radically altering our connection with automobiles. Product development challenges have evolved and are needed to be quickly addressed.

Established original equipment manufacturers (OEMs) are rushing to develop new products and achieve first-mover advantage. While new companies seek to compete and grab market share.

Although EV manufacturers have a huge development potential ahead of them, it is not without its obstacles. In this piece, we’ll look at some of the challenges that electric transportation firms face as they try to innovate in a cutthroat and turbulent industry.


Read: “Custom Product Development – What is it? And Why it is Beneficial?”

Product Development Challenges in the EV Manufacturing Domain

Choose the Appropriate Vehicle Design

There are no preconceived ideas about what an electric car should look like. Vehicles using traditional internal combustion engines were designed around a single component: the power plant. The designers of electric cars have a lot more scope. The viewpoint is both thrilling and terrifying. On the one hand, it’s exciting to see the variety of inventive concepts provided by both new and established businesses. Because of the adaptability of EV layout, certain concepts are required,  Also it changes the design engineer’s work and makes it more difficult than before. There are various techniques available to assist engineers to explore the unexplored frontiers of EV design, ranging from generative design to design optimization.


Regulate the Vehicle’s Thermal Performance

“While we’re on the subject of comfort, let’s take a look at the complicated issue of thermal comfort. That question was easy to answer in traditional vehicles: the engine’s heat helped to warm up the cockpit or defrost the windscreen. Furthermore, because the driving range was never a concern, batteries and electrical equipment could be used to heat seats or blast cold air as needed. But, with an electric car, how do you maintain thermal comfort without sacrificing range? And how can you accomplish good heat dispersion while ensuring that the batteries do not overheat? It is critical for the brand’s success to address the issue of thermal behavior throughout the concept stage of vehicle development. The comprehensive digital twin method balances energy and thermal parameters, as well as other important vehicle performance criteria including durability, noise and vibration, and driving dynamics.


Change Sensitivity & Bad Track Record

Every new technology faces challenges in achieving market adoption, and electric vehicles are no exception. They must not only overcome end-user resistance to change, but they have also become symbols of political and societal differences in some cases. Whether it’s because of climate change, fossil fuel entrenched interests, or those in the automotive business, the notion of electric mobility has only just begun to acquire mainstream acceptance and overcome biases.

We’ve only seen that change in the last few years when battery technology has made them a feasible option for the common motorist. Many individuals believe that buying an electric vehicle will require big adjustments in their driving habits. But in reality, these adjustments are minor. One of the most prominent instances is in the area of range and charging.


Expensive to Purchase And Operate, and Limited Selection

With the current crop of electric vehicles on the market, the elephant in the room is that they’re still incredibly costly. Additionally, there’s no genuine used EV market to speak of. New technology has always been expensive. But electric cars were so expensive in the last decade that only a few people could afford them. There’s also the matter of maintenance, which is frequently delegated to primary dealers.


Adapt To The Shifting Supply Chain Landscape

Engineering and producing an electric car alters the OEM-supplier relationship dramatically. To begin with, an electric motor has just roughly 200 separate components. Compared to at least 4000 in an internal combustion engine.

Manufacturers benefit from this substantial decrease in part number in a variety of ways. On the one hand, this might result in huge cost savings. Not only is purchasing parts cheaper but manufacturing EVs also allows OEMs to benefit from economies of scale by sourcing parts from fewer vendors. There are additional repercussions in terms of maintenance and total cost of ownership when there are fewer parts. It’s a lot easier to replace a single component now.


KloudPLM To Overcome Product Development Obstacles

Without the correct solution, product development challenges can be tough. Such as getting goods to market quickly while meeting customer requests, regulatory regulations, and supply chain interruptions.

Enterprise systems, such as cloud-based product lifecycle management (PLM) software, consolidate the whole product record. This allows manufacturers to keep track of customer requests, regulatory obligations, design revisions, CAPAs, and other procedures. Interoperability is ensuring the ability to aggregate the complete product design, which includes sensors, firmware, software, mechanical, and electrical components. This helps manufacturers manage rising product complexity as consumers’ expectations develop.

Read: “The New Era of Digital Transformation Through PLM”

Furthermore, the ability to seamlessly integrate the PLM system with component databases provides manufacturers with full visibility into current market availability and compliance information. Thus allowing them to source high-quality parts while staying compliant with environmental regulations.

Of course, there isn’t a single solution to all of these problems. However, at KloudPLM, we are confident that adopting a comprehensive digital twin strategy will assist in addressing the advancement. A step toward success is partnering with KloudPLM, depending on engineering services for technology transfer, and deploying the digital twin technique. Set up a demo with KloudPLM right now.


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