LIGHTWEIGHTING
pop-up production cells in relevant and remote locations. “Stilfold has huge potential for
vehicle manufacturing,” continues Nyvang. “Not only does it significantly lower the environmental impact of producing vehicles, but it can also speed up the manufacturing process and produce lighter vehicles that are easier to recycle at the end of their lives. We do this by folding steel over curves to form intricate, strong and lightweight new structures using locally-sourced materials and minimal component parts.” According to Stilride, the technology
is capable of delivering weight reductions of 40% while using 70% fewer components. Material costs and labour costs are also slashed by 20% and 25% respectively, offering manufacturers the possibility to optimise their material usage while improving the performance of their parts.
IMPROVING HGV EFFICIENCY In order to reach its improved efficiency estimates for HGVs, Stilride’s design team first worked out how they could build a semi-trailer
using Stilfold technology in order to decrease the trailer’s total weight and simplify its construction. In the design, the team reimagined the traditional ladder frame used in semi-trailers by creating an exoskeleton using origami- inspired steel folding. The outer shell is composed of two steel sheets with one main weld and eight strategically placed folds to give the trailer its necessary structure while keeping weight down. The designers then focused
on making the semi-trailer more aerodynamic and improving its material efficiency to make it strong yet light. The Stilfold trailer requires 90% fewer component parts compared to traditional models, can be constructed using 30% fewer materials, and would also weigh an estimated 2000kg less than traditional models, at 6000kg. The team aimed to simplify elements of the design and use fewer materials while retaining the trailer’s structural integrity. As a result, the design would improve the trailer’s performance by reducing the HGV’s fuel consumption and enabling it to carry heavier loads. Nyvang adds: “The technology could enable weight reduction for HGVs
by reducing the weight of the semi- trailers. This could enable the trailer to carry heavier loads, which means fewer journeys would be needed to transport the same amount of freight.”
ANALYSING THE DATA To work out the impact the new design could have, Stilride’s researchers analysed Swedish transportation data with a focus on the construction and mining sector. The data shows that in Sweden, 44 million journeys are made by HGVs annually, with over 494 million tonnes of goods being transported over 3.4 billion kilometres. Based on average maximum load limits and capacities, the company calculated that around 48 million tonnes of material are being transported by trailer in the mining and construction sector each year. Noting the Stilfold trailer weighs
two tonnes less than the semi-trailers currently in use, if just half of the 7,346,000 yearly journeys within the industry gained two tonnes of load capacity each year, this would create a load increase of 7,346,000 tonnes, representing 5% of the total yearly tonnage transported within the mining and construction sector in Sweden. On this basis, the company’s researchers estimate that this load increase would prevent 360,000 heavy load journeys each year. “As this new research shows, our
technology has the potential to significantly reduce HGVs’ impact on the planet, by rethinking how semi-trailers are used and produced through
innovative design,” Nyvang
adds. “This use case shows that by embracing change and innovation, it is possible to transform how heavily polluting industries operate, improving performance and efficiency whilst reducing emissions. “Our immediate focus remains on bringing our first electric
motorbike to market – but in future
we hope to bring innovations including a sustainable steel semi-trailer to market.”
A render of the Stilfold trailer construction
For more information visit
www.stilride.com
www.engineerlive.com 29
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