L3:An Integrated approach towards zero net emissions via lightweight manufacturing

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This is a feasibility project geared towards an integrated approach to enable Lightweight vehicles, manufactured at a Low cost to achieve Low emissions (L3). Lightweight materials are the next pit-stop in the challenge of reducing mass, and therefore curb reduce emissions, to improve fuel economy in the vehicle industry. But it has to be done economically. This project will develop a breakthrough cost-effective continuous extrusion process for composite beam manufacturing. The innovative continuous extrusion process will move away from traditional high-waste composite manufacturing methods. It will offer flexibility in the dimensions of the beam along its length, width and height, supporting end-users’ needs. The tailored and bespoke structural beams will require minimal tooling. The main project outputs are the continuous low-waste and affordable extrusion process. The sonication process developed at Loughborough University allows microstructure development that gives the required properties, supported by a controlled way of reinforcing with fibres. The underlying materials science has been demonstrated but requires some development in the area of transport. This project will take this and show that components can be manufactured, moving the technology from TRL 1/2 to TRL 3.