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

Objective

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).

Coordinator

FUNDACIO EURECAT
Net EU contribution
€ 723 250,00
Address
Avenida Universitat Autonoma 23
08290 Cerdanyola Del Valles (Barcelona)
Spain

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Region
Este Cataluña Barcelona
Activity type
Research Organisations
Non-EU contribution
€ 0,00

Participants (9)

LULEA TEKNISKA UNIVERSITET
Sweden
Net EU contribution
€ 397 531,00
Address
Universitetsomradet Porson
971 87 Lulea

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Region
Norra Sverige Övre Norrland Norrbottens län
Activity type
Higher or Secondary Education Establishments
Non-EU contribution
€ 0,25
CENTRO RICERCHE FIAT SCPA
Italy
Net EU contribution
€ 350 750,00
Address
Strada Torino 50
10043 Orbassano

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Region
Nord-Ovest Piemonte Torino
Activity type
Research Organisations
Non-EU contribution
€ 0,00
AUTOTECH ENGINEERING SPAIN SL
Spain
Net EU contribution
€ 524 248,00
Address
Calle Alfonso Xii 16
28014 Madrid

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Region
Comunidad de Madrid Comunidad de Madrid Madrid
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Non-EU contribution
€ 0,00
VIRTUAL VEHICLE RESEARCH GMBH
Austria
Net EU contribution
€ 491 250,00
Address
Inffeldgasse 21 A
8010 Graz

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SME

The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.

Yes
Region
Südösterreich Steiermark Graz
Activity type
Research Organisations
Non-EU contribution
€ 0,00
GEMMATE TECHNOLOGIES SRL
Italy
Net EU contribution
€ 570 250,00
Address
Via Reano 31
10090 Buttigliera Alta

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SME

The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.

Yes
Region
Nord-Ovest Piemonte Torino
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Non-EU contribution
€ 0,00
FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
Germany
Net EU contribution
€ 495 590,00
Address
Hansastrasse 27c
80686 Munchen

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Region
Bayern Oberbayern München, Kreisfreie Stadt
Activity type
Research Organisations
Non-EU contribution
€ 0,00
IMC FACHHOCHSCHULE KREMS GMBH
Austria
Net EU contribution
€ 189 750,00
Address
Piaristengasse 1
3500 Krems

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Region
Niederösterreich Waldviertel
Activity type
Higher or Secondary Education Establishments
Non-EU contribution
€ 0,00
AEROBASE INNOVATIONS AB
Sweden
Net EU contribution
€ 160 625,00
Address
Kompanivagen 35
974 44 Lulea

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SME

The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.

Yes
Region
Norra Sverige Övre Norrland Norrbottens län
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Non-EU contribution
€ 0,00
ASOCIACION ESPANOLA DE NORMALIZACION
Spain
Net EU contribution
€ 68 500,00
Address
Calle Genova 6
28004 Madrid

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Region
Comunidad de Madrid Comunidad de Madrid Madrid
Activity type
Other
Non-EU contribution
€ 0,00