Student-Built EV: Modular Design Prioritizes Repairability | IEEE Spectrum

The electric vehicle landscape is rapidly evolving and a new project from students at Eindhoven University of Technology in the Netherlands is challenging conventional wisdom about EV design and maintenance. The Aria EV isn’t necessarily groundbreaking in its performance specifications, but its core concept – designed for repairability by the owner – could represent a significant shift in how we think about vehicle ownership and sustainability. The project, initiated in 2024, aims to address the increasing difficulty of repairing modern electric vehicles, a concern gaining traction with the growing “Right to Repair” movement.

A Different Approach to EV Architecture

Most electric vehicles today feature large, integrated battery packs that are complex and expensive to replace. The Aria team, operating under the university’s Ecomotive structure – which functions much like a startup – took a different tack. Instead of a single, monolithic battery, Aria utilizes six smaller, modular battery modules, each weighing approximately 12 kilograms (about 26 pounds). This design allows for individual modules to be easily removed, swapped, and replaced, even by the vehicle owner. The total battery capacity is 13 kilowatt-hours (kWh), which is smaller than the 50-80 kWh packs common in many mainstream EVs like the Chevrolet Bolt EV, but sufficient for urban driving scenarios.

This modularity isn’t limited to the battery. The Aria EV is constructed from separate components – body panels, electronic elements, and other parts – that can be individually replaced. A scratch or dent doesn’t necessitate a costly repair at a body shop; the damaged panel can be clicked off and replaced in minutes. This approach is rooted in the “Right to Repair” philosophy, which advocates for consumer access to the parts, tools, and information needed to fix their own devices, and is gaining momentum in both Europe and the United States.

How Modular Batteries Work in Practice

The Aria’s battery modules are secured beneath the vehicle floor using a bottom-latch system. When the vehicle is powered down, the latches release, allowing a module to be lowered and removed. Integrated interlocks ensure high-voltage connections are isolated before removal, prioritizing safety. This combination of mechanical and software safeguards aims to make component-level replacement straightforward. Although, as Joe Borgerson, a research coordinator at Ohio State University’s Center for Automotive Research, points out, mixing new and aged battery modules can present technical challenges. Maintaining consistent performance across modules over the vehicle’s lifespan requires careful management.

The team has also developed a diagnostic app, accessible via a USB-C port, that provides users with a 3D visualization of the vehicle’s status, identifies faults, and offers step-by-step repair instructions. The necessary tools are even stored within the vehicle itself, further reducing barriers to self-maintenance. This integrated system aims to empower owners to extend the life of their vehicle and reduce reliance on specialized service centers.

Trade-offs and Challenges of Modularity

While Aria champions modularity, the broader automotive industry generally favors integrated systems to streamline manufacturing and reduce costs. Dividing systems into removable units introduces additional interfaces – mechanical fasteners, electrical connectors, seals, and safety interlocks – each of which must withstand vibration, temperature fluctuations, and potential crash forces. As Borgerson notes, these interfaces can add mass and complexity compared to tightly integrated battery structures, and they also consume space that could otherwise be used for energy storage.

Matilde D’Arpino, an assistant professor of mechanical and aerospace engineering at Ohio State, highlights that EV batteries are already modular internally, with cells forming modules and modules forming packs. However, making modules externally replaceable introduces new validation requirements. High-voltage isolation, thermal performance, and crash integrity must remain robust even when energy storage is divided into removable segments. Essentially, simplifying battery access for users necessitates a cascade of system-level design considerations impacting safety, thermal management, and overall vehicle structure.

Beyond Batteries: The Broader Implications

The Aria project isn’t solely about batteries. It’s a demonstration of a broader philosophy: designing vehicles with longevity and user repairability in mind. This approach could have significant implications for sustainability, reducing electronic waste and extending the lifespan of valuable resources. It also challenges the traditional automotive business model, which often relies on service revenue and planned obsolescence. The team hopes to inspire policymakers to push for “Right to Repair” directives specifically for the automotive market, and to provide automakers with pathways to comply with these regulations.

However, consumer preferences also play a crucial role. Currently, buyers often prioritize longer driving range and lower sticker prices – factors that can conflict with designs focused on repairability. The added cost, weight, or complexity associated with modular designs must be weighed against these consumer priorities. The success of concepts like Aria will depend on whether regulators, manufacturers, and consumers collectively decide that repairability is a valuable feature worth prioritizing.

What’s Next for Repairable EVs?

The Aria EV is currently a prototype and is not road legal. Its primary purpose is to demonstrate the feasibility of repairability-focused design. The team plans to continue refining the design and exploring potential commercial applications. The broader industry is likely to see increased scrutiny of vehicle repairability as “Right to Repair” legislation gains traction. Economic incentives may also emerge from fleet operators or long-term owners who benefit from replacing components rather than entire systems. The future of repairable EVs will depend on a complex interplay of technological innovation, regulatory pressure, and consumer demand. Further research will be needed to assess the long-term reliability and cost-effectiveness of modular designs, and to develop standardized components and repair procedures that can be widely adopted.