Stilfold technology together with recycled aluminium sheet for sustainable mobility - LightRide

Purpose and goal:

Collaboration between material suppliers, designers, and manufacturers is required to utilize the Stilfold process and more efficient ways of using recycled aluminum. CAE was performed to optimize the forming, resulting in a robust manufacturing process. Everything contributes to broadening the company´s perspective with a focus on feasibility, which results in SMEs getting a more solid basis for having constructive discussions with partners. Scaling up, automating and digitizing are necessary.

Expected results and effects:

Recycled aluminum offers an attractive opportunity to reduce environmental impact and costs, but ensuring that the material meets the technical requirements is important. Cost optimization is an important factor in the development of new products. CAE must be integrated as a predefined part of product development. Scaling up, automating, and digitizing the Stilfold process is essential to maximize its potential and meet future market demands.

Approach and implementation:

By carrying out simulations, analyses, and investigating how the material affects the manufacturing process and the properties of the final product. Thus, we created an efficient and sustainable production method that reduced the environmental impact. We encountered unexpected challenges, mainly regarding the homogeneity of the material and process improvements. To manage resource usage, the project was extended by 3 months. Through an innovative collaboration, we were able to find new solutions