RESEARCH NEWS
Future vehicle chassis project from GMG
Gordon Murray Group( GMG) has announced a new consortium project that is working to create a new generation of ultra-lightweight, environmentally friendly vehicle structures. In three years, the project aspires to create a new vehicle monocoque architecture that is lighter and stronger as well as 50 % less carbon-intensive.
‘ Project M-LightEn’( Monocoque architecture – Lightweight and Low Energy) has funding support from Innovate UK and the Advanced Propulsion Centre( APC). The venture is projected to create as many as 160 new jobs across the Gordon Murray Group, and partners Carbon ThreeSixty, Constellium and Brunel University( London, UK).
Gordon Murray Group will lead the project in its mission to research, design, build and validate a series of digital and physical monocoque prototypes. The target result is the validation of several new solutions paving the way for the development and industrialisation of innovative monocoque structures for a portfolio of new vehicles.
“ With a goal of achieving even greater performance through further weight reduction, the process could enable future Gordon Murray Automotive( GMA) vehicles to
achieve the lowest lifecycle carbon footprint of any supercar,” GMG explained.
GMG’ s strategy and business director, Jean-Phillipe Launberg, said:“ Alongside Gordon Murray Automotive’ s niche supercar application, Project M-LightEn will enable decarbonisation across the wider automotive industry by shortening and de-risking the path to market for innovative new materials and processes.”
Targeting a reduction in vehicle lifecycle CO₂ by a third or more, the consortium will use AI to optimise designs, while also developing new materials and advanced manufacturing processes. Constellium and Brunel aim to provide STEP-enhanced, ultrahigh-strength extrusions made from 80 % recycled UK consumer scrap aluminium within the monocoque structure. Production of lightweight carbon fibre composite components by Carbon ThreeSixty is expected to achieve near-zero-waste levels in manufacturing and low weight through the precision‘ tailored-fibre-placement’ production process.
Prof. Geoff Scamans, Professor of Metallurgy, Brunel University of London, added:“ This project represents an excellent opportunity to exploit the high-strength extrusion aluminium alloy technology developed in the EPSRC strain-enhanced precipitation in aluminium( STEP Al) programme, funded as an EPSRC Prosperity Partnership between Constellium and Brunel. The M-LightEn project will use the highest performing aluminium extrusion alloys formulated from recycled end-of-life aluminium using novel thermomechanical processing techniques developed in this fiveyear programme.”
The first phase of the project is already underway, exploring new materials and‘ joining’ techniques. From late 2027, developments from M-LightEn are projected to be available for low-volume commercial use, with larger, mainstream applications rolled out thereafter. n
L-R: Tom Eriksson, EVP and Head of Strategic Research, Göran Björkman, CEO and President, Björn Bosbach, Senior Project Manager New Technology and Mikael Blazquez, EVP and Head of Strategy, M & A and IT( Alleima). Thermal spraying.
Thermal spraying research prototype
Thermal spraying is an advanced manufacturing method in which material in powder or wire form is melted and sprayed onto a surface to create a coating with specific properties. Alleima, a global manufacturer of advanced stainless steel and specialty alloys, industrial heaters, is now investing in this technology to develop new products in sustainable energy. For example, the technology can be used in the production of components for green hydrogen through to electrolysers. The first prototype of the coated material, Alleima confirmed, has already been sent to a customer.
Thermal spraying enables coatings with specific properties that are crucial for improving products( such as electrolyses for the production of green hydrogen). Green hydrogen, produced by the electrolysis of water using renewable energy, plays a central role in the transition to a carbon-free economy. Thermal spraying enables the development and industrial production of key components in an electrolysis stack.
“ This investment is part of the company’ s long-term strategy to drive innovation and create sustainable solutions. It is a pilot that will primarily be used for research purposes but will also be used for small-scale production when possible. By using this technology in our manufacturing processes, we can offer advanced materials and components that meet the high demands of hydrogen production. This initially includes the development of components for electrolyser cells, but also other applications that require robust and durable coatings,” said Tom Eriksson, Head of Strategic Research, Alleima.
The technology will eventually make it possible to develop products that replace expensive material solutions. This will help to reduce the cost of electrolyser stacks, which in turn can promote the increased use of green hydrogen and therefore reduce carbon emissions, added Alleima. n
www. alleima. com
18 | ismr. net | ISMR June 2025