Next-Generation Structural Safety for Electric and Commercial Vehicles

The rapid electrification of passenger and commercial transport has radically changed structural safety engineering. The combination of high-voltage lithium-ion battery systems, lightweight multi-material structures, and connected vehicle platforms introduces complex thermo–electro–mechanical interactions, which go beyond traditional crashworthiness considerations. Electric vehicles are highly susceptible to structural deformation that can propagate through battery enclosures to cause internal short circuits, thus leading to thermal runaway, with mechanical integrity having a direct connection to electrochemical safety [31,32]. Meanwhile, commercial vehicle electrification is characterized by increased load demands, durability requirements, and regulatory requirements under increasingly stringent international safety standards [33]. The recent developments in multi-scale modeling, lightweight materials, and digital engineering have enhanced energy absorption during the crash and structural optimization, but there are still several challenges in the development of battery protection, intrusion control, and post-crash electrical safety in unified design frameworks [34]. The introduction of digital twins and predictive modeling on the basis of data provides new opportunities for lifecycle-based safety analysis and adaptable structural design [35]. This review examines current trends in next-generation structural safety of electric and commercial vehicles, important gaps in research regarding multi-physics coupling and standardization, and an integrated risk-based design that may be aligned with structural crash response, battery misuse prevention and regulation, and intelligent monitoring.