A Systematic Review of Alternative Manufacturing Process Selection for Sustainable Electric Vehicle Production

The environmental performance of electric vehicles depends in part on the processes relied upon in the manufacture of their components. The systematic review presented in this manuscript examines alternative manufacturing processes for lightweight structures and battery-related components, including additive manufacturing, laser-based processes, hydroforming, friction stir welding and composite fabrication. Searches across nine databases and platforms ran from March 2025 to August 2026. Screening and extraction were subsequently performed. The study compares the reported benefits and limitations in material efficiency, energy demand, waste generation and industrial scalability, with the economic feasibility and circular economy considerations informing the discussion. The key argument is that process selection must account for component requirements, materials, production volume and assessment boundaries. The literature-guided comparison identifies potential benefits and trade-offs. The review identifies hybrid additive–subtractive manufacturing as a promising option for electric vehicle components requiring both geometric complexity and precision finishing, with sustainability benefits evaluated against component-specific production conditions. This review further identifies priorities for component-specific life cycle assessment, transparent evidence synthesis, cost evaluation and industrial validation to support sustainable electric vehicle manufacturing.