Low-speed (20 mph) accidents saw year-on-year increase of 31% (2016-2017, Department of Transport); injury increase was broken down as fatal (+79%), serious (+47%), and slight (+42%). A crash box is a thin-walled structure attached between the vehicle bumper structure and the side rail to improve crash performance in low-speed accidents. The determination of the crash box geometry is important to absorb the impact energy, since the installation space of the crash box is not very large. Conventional crash boxes (i.e. those manufactured from steel or aluminium) exhibit high-peak force and have no way of controlling the rate of deceleration following a crash. Composite alternatives are limited in use due to unpredictable failure. PROTECT is an innovative new crash-box with better impact energy-absorption capabilities; enabling minimal damage to the vehicle itself, its occupants, and other road users. In the event of a low-speed collision, PROTECT will help reduce damage to the vehicle, its occupants and the wider public. This will result in safer roads and vehicles, along with minimised repair costs. As a result of this innovative solution, the consortium partners expect to create 227 jobs and generate cumulative revenues of £51.6 million by 2029\.

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. This technology could also work for other sectors e.g. heavy goods vehicles and rail. The main project outputs are the continuous low-waste and affordable extrusion process. The sonication process developed at Loughborough University allows microscture development that gives the required properties. 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 low to mid TRLs.

The OptiMotor project aims to deliver a **new generation of synchronous reluctance motors (SynRMs) that are adaptable, efficient, and sustainable**. The resulting e-motor product will be **suitable for a wide range of applications, from small electric vehicles and e-bikes to drones and industrial machinery**. This will be achieved through a **highly innovative approach that combines advanced composite materials with state-of-the-art 3D printing technology and AI-driven design optimisation.** OptiMotor's SynRM design thus pushes the boundaries of **performance, efficiency, and sustainability** **by enhancing the motor's energy efficiency and torque-to-weight ratio, critical characteristics for e-mobility applications.** The **key technological innovation** lies in the unique fabrication methodology, based on **additive manufacturing** techniques that combine ferromagnetic alloy particles with mechanically strong nylon/glass fibers, using **specifically engineered 3D printing filaments** based on bio-polymer compounds. This composition results in a rotor with superior magnetic and mechanical properties, tailored for SynRMs. The **adaptive AI-driven design approach** allows for rapid optimisation of the motor, ensuring optimal performance across a wide range of operating conditions. Another crucial aspect of OptiMotor is its **commitment to environmental sustainability**. The project actively reduces the use of copper, a resource-intensive component in traditional motor manufacturing, and completely avoids rare earth permanent magnets. Instead, **the bulk of the proposed motor is made up of recyclable bio-polymer compounds, significantly lowering the environmental footprint.** This aligns well with the growing demand for eco-friendly transportation solutions and contributes to a more sustainable future for e-mobility. Beyond its performance enhancements, OptiMotor's design and manufacturing approach also ensures smoother operation, with precisely balanced rotors that **minimise vibrations and noise**. This not only **enhances the user experience but also contributes to quieter and hospitable urban environments**, making OptiMotor's SynRMs an attractive choice for a wide range of e-mobility applications. From a **market perspective**, OptiMotor's technological innovations are expected to **reduce costs associated with manufacturing and maintenance of electric motors**. As e-motor production scales up, the cost of copper and rare earth metals for permanent magnets is expected to increase dramatically. By switching to composite materials and innovative manufacturing techniques, OptiMotor has the potential to **make electric vehicles and drones more affordable and accessible**, aligning with the growing market demand for cost-effective and eco-friendly transportation solutions and potentially **becoming a leading choice for e-mobility solutions in the near future that will support the transition to a more sustainable future of transportation.**

Awaiting Public Project Summary

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.