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TRIMIS

Flexible and hybrid manufacturing of green aluminium to produce tailored adaptive crash-tolerant structures

PROJECTS
Funding
European
European Union
Duration
-
Geo-spatial type
Other
Total project cost
€3 971 744
EU Contribution
€3 971 744
Project Acronym
FLEXCRASH
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Multimodal icon
Transport policies
Safety/Security
Transport sectors
Passenger transport

Overview

Call for proposal
HORIZON-CL5-2021-D6-01
Link to CORDIS
Background & Policy context

Handling unexpected events is difficult, particularly in today’s complex manufacturing environment. But it’s possible. The EU-funded FLEXCRASH project will develop a flexible and hybrid manufacturing technology by applying surface patterns using additive manufacturing onto preformed parts. Hybrid manufacturing offers a property tailoring capacity that allows the development of a new type of crash-tolerant structure with outstanding performance in an imminent crash. The project will define these structures according to the collision parameters identified by the different mixed traffic scenarios and are the ideal solutions for active safety devices. The technology can be applied to other safety-related structures in vehicle parts, decreasing the number of materials and processes used in crash structure manufacturing and reducing manufacturing costs.

Objectives

Flexcrash aims to develop a flexible and hybrid manufacturing technology based on applying surface patterns by additive manufacturing onto preformed parts. Aluminium alloys have been selected as the optimum material to build high performance structures, addressing both lightweight and environmental sustainability. They provide better recyclability, affordability (low CRM content), and costs than other material alternatives that would need complex developments for joining, recycling, and manufacturing. The property tailoring capacity offered by hybrid manufacturing will permit to develop a new type of crash-tolerant structures with outstanding performance under a wide range of impact angles and unexpected crash conditions. Structures will be defined according to the collision parameters identified by the different mixed traffic scenarios. Such tailored structures are the ideal solutions for dynamic active safety devices that allows displacement of crash structures to optimally face an imminent crash. Considering that the frontal crash is the most common (70%), a front-end structure has been chosen as demonstrator to validate the manufacturing developments, the modelling approach and the testing methodologies. The flexibility of the proposed technology will facilitate its transferability to other safety-related structures in vehicle’s locations with higher risk for passenger’s injuries while decreasing the number of materials and processes used to manufacture a crash structure. Simplify supply chain will turn into 20% manufacturing costs saving and reduce the risk of disruption.

Virtual testing with improved reliability, validated by crash tests, will be used to propose new testing configurations, looking at the next step towards standardization. The application of Flexcrash solutions to the whole BiW offers a lightweighting potential up to 20% with improved safety (toward 50% reduction of passenger’s injuries and fatalities).

Funding

Specific funding programme
HORIZON.2.5 - Climate, Energy and Mobility
HORIZON.2.5.7 - Clean, Safe and Accessible Transport and Mobility
HORIZON.2.5.8 - Smart Mobility
Other Programme
HORIZON-CL5-2021-D6-01-10 Testing safe lightweight vehicles and improved safe human-technology interaction in the future traffic system
Funding Source
Horizon Europe

Partners

Lead Organisation
Organisation
FUNDACIO EURECAT
Address
AVENIDA UNIVERSITAT AUTONOMA 23, 08290 CERDANYOLA DEL VALLES (BARCELONA), Spain
Organisation website
EU Contribution
€723 250
Partner Organisations
Organisation
Lulea Tekniska Universitet
Address
Universitetsomradet Porson, 971 87 Lulea, Sweden
Organisation website
EU Contribution
€397 531
Organisation
ASOCIACION ESPANOLA DE NORMALIZACION
Address
CALLE GENOVA 6, 28004 MADRID, Spain
Organisation website
EU Contribution
€68 500
Organisation
IMC FACHHOCHSCHULE KREMS GMBH
Address
PIARISTENGASSE 1, 3500 KREMS, Austria
EU Contribution
€189 750
Organisation
CENTRO RICERCHE FIAT SCPA
Address
STRADA TORINO 50, 10043 ORBASSANO, Italy
Organisation website
EU Contribution
€350 750
Organisation
FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
Address
HANSASTRASSE 27C, 80686 MUNCHEN, Germany
Organisation website
EU Contribution
€495 590
Organisation
Virtual Vehicle Research Gmbh
Address
INFFELDGASSE 21 A, 8010 GRAZ, Austria
Organisation website
EU Contribution
€491 250
Organisation
AUTOTECH ENGINEERING SPAIN SL
Address
CALLE ALFONSO XII 16, 28014 MADRID, Spain
EU Contribution
€524 248
Organisation
AEROBASE INNOVATIONS AB
Address
KOMPANIVAGEN 35, 974 44 LULEA, Sweden
EU Contribution
€160 625
Organisation
Gemmate Technologies Srl
Address
VIA REANO 31, 10090 BUTTIGLIERA ALTA, Italy
EU Contribution
€570 250

Technologies

Technology Theme
Electric road vehicles
Technology
Aluminium front vehicle structure
Development phase
Research/Invention

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