Topology Optimization and Lightweight Chassis Design for Electric Vehicles: A Review Based on Finite Element Analysis

The rapid growth of electric vehicles (EVs) has intensified the need for lightweight and structurally efficient chassis systems to improve driving range, safety, and energy efficiency. Reducing vehicle weight directly lowers energy consumption and enhances battery performance; however, weight reduction must not compromise strength, stiffness, or crashworthiness. This review paper summarizes recent research progress in topology optimization and finite element analysis (FEA) techniques applied to electric vehicle chassis design. Various optimization approaches such as density-based methods, evolutionary algorithms, and size–shape–topology optimization are discussed. The use of advanced lightweight materials including aluminum alloys, high-strength steel, and composite materials is reviewed with respect to manufacturability and cost. Case studies from the literature demonstrate that topology optimization effectively identifies material distribution while FEA validates stress, deformation, modal behavior, and crash performance of optimized chassis structures. Challenges such as multi-objective optimization, fatigue life prediction, integration of battery pack loads, and real-world crash scenarios are highlighted. The review concludes that the combined use of topology optimization and FEA provides a powerful framework for achieving lightweight, safe, and efficient EV chassis designs, and future research should focus on AI-driven optimization, digital twins, and sustainability-based design criteria.