Integrated Structural and Impact Optimization for a Lightweight 6-Wheel Electric Truck Chassis

Srirat, Jirasak; Theppakdee, Jakkarin; Tiemkhum, Jedtawat; Karimee, Nayef; Homsnit, Thonn; Jongpradist, Pattaramon

doi:2026.27.3.1051

International Journal of Automotive Technology > Volume 27(3); 2026 > Article

Body and Safety, Manufacturing, Materials and Recycling

International Journal of Automotive Technology 2026;27(3): 1051-1062.
doi: https://doi.org/10.1007/s12239-025-00341-6

Integrated Structural and Impact Optimization for a Lightweight 6-Wheel Electric Truck Chassis

Jirasak Srirat^1,3, Jakkarin Theppakdee², Jedtawat Tiemkhum², Nayef Karimee², Thonn Homsnit³, Pattaramon Jongpradist^2,3

¹KMUTT Ratchaburi Learning Park, King Mongkut’s University of Technology Thonburi, Ratchaburi, 70150, Thailand
²Department of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, 10140, Thailand
³Future Automotive Structure Research Group (FASt), Mobility and Vehicle Technology Research Center, King Mongkut’s University of Technology Thonburi, Bangkok, 10140, Thailand

Corresponding Author. Pattaramon Jongpradist , Email. pattaramon.tan@kmutt.ac.th

Received: July 18, 2025; Revised: August 16, 2025 Accepted: August 16, 2025. Published online: September 3, 2025.

ABSTRACT

This study presents a comprehensive optimization strategy for the chassis design of a 6-wheel electric vehicle (EV) truck, focusing on weight reduction while maintaining structural integrity and crash safety. Unlike previous studies that prioritize either weight minimization or static performance, this work integrates crashworthiness constraints to ensure occupant safety under dynamic impact scenarios. The proposed method optimizes the dimensions and positions of side rails and cross members, addressing critical constraints, such as bending stiffness, safety factor, and frontal crash deformation. Three optimization approaches are evaluated: Case I, which optimizes only side rails, achieves a minor 8 kg reduction; Case II, which extends optimization to cross members, leads to a 27.43% mass reduction but compromises crash safety. The proposed method strikes a balance, reducing chassis weight by 13.08% to 206 kg while meeting all structural and crash safety requirements. This study underscores the importance of a holistic optimization framework that simultaneously enhances weight efficiency and crashworthiness, contributing to the advancement of lightweight, safe EV truck designs.

Key Words: Optimization · Structural integrity · Crash safety · Chassis design · Electric vehicles