In an era where electric vehicles (EVs) are becoming increasingly prevalent, a group of inventive students from the Eindhoven University of Technology in the Netherlands is challenging the status quo. Their creation, the Aria EV, offers a unique proposition: a self-repairable electric car designed with modularity at its core.
Initiated in 2024, the Aria project brought together around 20 students under the university’s Ecomotive team, functioning akin to a startup. Participants were tasked with developing a vehicle in a setting reflective of real-world industry practices. The primary aim, according to team spokesperson Sarp Gurel, was to ensure the car was as accessible and repairable as possible. Although the Aria EV is not yet road legal, its purpose is to demonstrate the feasibility of embedding repairability into the architecture of electric vehicles from the outset.
Innovative Battery Construction
The Aria EV features a total battery capacity of 13 kilowatt-hours (kWh), significantly less than the 50 to 80 kWh typically found in commercial electric sedans and SUVs. This capacity is more suitable for a lightweight, urban-centric vehicle. What sets Aria apart is the innovative approach to battery design. Instead of a single, large battery pack, the team opted for six smaller, more manageable modules, each weighing about 12 kilograms. This design choice allows for easy removal, swapping, and replacement by a single person.
These modules are housed in secure compartments beneath the vehicle floor, accessible via a bottom-latch system. The design includes mechanical and software elements to facilitate safe module replacement, embodying the concept of “repairability by design.” However, integrating different modules throughout the vehicle’s lifespan poses technical challenges that must be addressed.
Joe Borgerson, from Ohio State University‘s Center for Automotive Research, highlights the complexity of mixing new and aged battery modules. Borgerson, who has extensive experience with battery pack design through the U.S. Department of Energy‘s Battery Workforce Challenge, states, “Our team is integrating a student-designed pack into a Stellantis vehicle platform, which has given me deep exposure to both automaker design philosophy and high-voltage EV architecture.”
To aid in vehicle maintenance, the Aria team developed a diagnostic app that connects via USB-C. This app offers a 3D visualization that identifies faults, locates issues, and provides repair instructions, making vehicle maintenance straightforward for users.
Exploring the Challenges of Modularity
The broader EV industry trend leans towards integrated systems to simplify manufacturing and reduce costs, contrasting with Aria’s modular approach. This design treats energy storage as a replaceable subsystem, which may or may not scale to larger vehicles.
Borgerson points out that dividing systems into removable units introduces additional interfaces—mechanical fasteners, electrical connectors, and safety interlocks—that must withstand operational stresses. While this adds complexity and mass, it may also provide a pathway for more user-friendly repair solutions.
According to Matilde D’Arpino of Ohio State University, while EV batteries already have a degree of internal modularity, making them externally replaceable introduces new validation challenges. Safety and performance must remain robust despite these changes.
As right-to-repair legislation in Europe and the United States gains traction, there could be a push for automakers to reconsider sealed battery architectures. Such changes would require significant shifts in supply chains and certification processes.
Ultimately, the Aria EV challenges traditional priorities in vehicle design by emphasizing repairability. Whether this approach gains mainstream acceptance will depend on a confluence of regulatory, manufacturing, and consumer changes.
Original Story at spectrum.ieee.org