Development of a Range-Extended Electric Vehicle Powertrain for an Integrated Energy Systems Research Printed Utility Vehicle

Johney Green, Paul Chambon, Scott Curran, Shean Huff, Lonnie Love, Brian Post, Robert Wagner, Roderick Jackson

Research output: Contribution to journalArticlepeer-review

40 Scopus Citations


Rapid vehicle and powertrain development has become essential to for the design and implementation of vehicles that meet and exceed the fuel efficiency, cost, and performance targets expected by today's consumer while keeping pace with reduced development cycle and more frequent product releases. Recently, advances in large-scale additive manufacturing have provided the means to bridge hardware-in-the-loop (HIL) experimentation and preproduction mule chassis evaluation. This paper details the accelerated development of a printed range-extended electric vehicle (REEV) by Oak Ridge National Laboratory, by paralleling hardware-in-the-loop development of the powertrain with rapid chassis prototyping using big area additive manufacturing (BAAM). BAAM's ability to accelerate the mule vehicle development from computer-aided design to vehicle build is explored. The use of a hardware-in-the-loop laboratory is described as it is applied to the design of a range-extended electric powertrain to be installed in a printed prototype vehicle. The integration of the powertrain and the opportunities and challenges it presents are described in this work. A comparison of offline simulation, HIL and chassis rolls results is presented to validate the development process. Chassis dynamometer results for battery electric and range extender operation are analyzed to show the benefits of the architecture.

Original languageAmerican English
Pages (from-to)99-110
Number of pages12
JournalApplied Energy
StatePublished - 2017

Bibliographical note

Publisher Copyright:
© 2017 The Authors

NREL Publication Number

  • NREL/JA-4A00-68390


  • Additive manufacturing
  • Hybrid vehicles
  • Natural gas
  • Printed vehicle
  • Range extender
  • Rapid prototyping


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