Design and Structural Analysis of Hybrid Composites for EV Bumper Panels

Abstract

This study presents a novel coconut coir/E-glass hybrid composite for electric vehicle (EV) bumper panels, tackling the demand for lightweight, crash-resistant, and sustainable automotive materials. While synthetic fiber composites currently prevail, their environmental footprint and cost pose challenges for long-term use. Here, coir, a renewable, affordable natural fiber, is combined with E-glass (15 vol% each) in a polyester matrix, striking a balance between eco-efficiency and mechanical strength. Finite element analysis (FEA) simulations under static, modal, and dynamic loads reveal the composite’s enhanced energy absorption, with 6.3% greater total deformation (0.08427 m vs. 0.079294 m) during frontal impact and 1.3% higher directional deformation (0.079362 m vs. 0.078359 m) during side impacts compared to conventional polypropylene (PP+EPM-TD15). The design also improves stress distribution (1.6528 × 10⁹ Pa vs. 1.636 × 10⁹ Pa), increases structural flexibility and improves energy dissipation under dynamic loading with a 18.3% lower natural frequency (5.5886 Hz vs. 6.8412 Hz). These results affirm coir’s potential as a sustainable reinforcement, matching synthetic material’s crashworthiness while supporting weight reduction goals. Addressing gaps in dynamic performance and scalability from prior research, this work offers a blueprint for next-generation EV materials aligned with global sustainability objectives. The findings highlight bio-hybrid composite’s promise in automotive safety systems, advancing decarbonization efforts without sacrificing structural reliability.