COMPOSITES


of topology and topometry optimisation to determine the optimum load paths. While more than 75 load cases were considered before completion, the optimisation focused on the three most relevant cases, including torsional stiff ness and rear crash. As the digital work progressed, a testing and manufacturing campaign was deployed to validate materials and assess the processability and compatibility with JLR paint processes.” In parallel to this, the digital


design was refi ned with Design for Manufacture (DfM) inputs. “Key features and critical geometries were validated through physical experimentation using demonstrator tooling,” Sicard adds. “Specifi c tests were also performed on manufactured demonstrator components.”


ONE STEP FURTHER In February 2021 JLR doubled down on its all-electric business with the launch of its Reimagine strategy. However, the Tucana project in its original concept was not meeting the company’s new sustainability ambitions, Sicard acknowledges: “Through Reimagine, JLR is looking holistically at sustainability and is transforming in an all-electric business,” Sicard explains. “JLR will be preventing the emission of millions of tonnes of CO2


e by delivering electric


models of all its luxury vehicles by 2030. JLR’s approach to addressing environmental impacts goes beyond tailpipe emissions, aiming to achieve a more resource eff icient economy through reducing waste and repeated circulation of products and materials – use less, extend the life of what we have, and reuse wherever possible. With an updated approach to sustainable composites, eff orts have been refocused on redefi ning our materials roadmap, bridging the sustainability and circularity gaps on materials.” In particular, the company’s


composite material roadmap has shifted towards sustainable and circular materials that display high- performance properties. “The fi rst and short-term milestone is


the development of high-performance and low CO2


composite materials,”


explains Sicard. “Learnings from Tucana highlighted virgin carbon fi bre as the main contributor to the concept


WHAT’S NEXT


As Sicard attests, historically end-of-life management and effi cient recovery of composite materials have been challenging. “In its original scope,


The SOCA project focused on the performance and viability of sustainable material alternatives


Tucana presented diffi culties regarding both dismantling and segregation,” he says. “However SOCA, which aimed at decarbonising the manufacturing of composite components for automotive, offered a viable route to market for reducing the environmental impact of carbon fi bre components. The adoption of material derived from SOCA would fi rst target JLR current carbon fi bre components with the goal of decarbonising their manufacturing. Then, they would match the end-of-life requirements and the current availability of materials in the supply chain. Longer term, as the supply chain scales up, the ambition is to roll this out on future JLR vehicles.”


The demonstrator showcased how the manufacturing of composite components could be decarbonised


CO2 footprint -or global warming


potential (GWP) – therefore, we are looking at materials originating from recycled feedstock, natural fi bre, or non- oil-based, as credible opportunities.” With these circular economy


principles embedded, JLR is now investigating technologies capable of reducing waste and energy, or enhancing the properties of these innovative sustainable materials whilst being careful of their compatibility with its fi nal products and business case. “Our latest Sustainably Optimised


Composite Automotive (SOCA) project reused the Tucana design to investigate the performance and viability of sustainable material alternatives,” Sicard continues. “Following the same framework,


we collaborated with partners to manufacture the optimised load path, parts and completed the assembly of two full-scale demonstrators, exhibited at Cenex Expo and the Advanced Engineering Show in 2024.” According to Sicard, the SOCA


project demonstrated that the Tucana CO2


footprint could be improved by


around 60% and compete with the original aluminium structure CO2


-wise,


while remaining lighter and stiff er. “Results and learnings from projects


like Tucana or SOCA are compatible with JLR sustainability and circularity ambitions, compliant with legal requirements and supporting the transition to a net-zero and BEV future, without compromising on quality,” he adds.


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