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Dec 10, 2023

'Industrial origami' manufacturing technology could make heavy transportation greener

HGVs (Heavy Goods Vehicles) are responsible for almost a fifth (19%) of domestic

HGVs (Heavy Goods Vehicles) are responsible for almost a fifth (19%) of domestic transport emissions in the UK and over a quarter across Europe. But new research suggests that constructing HGV semi trailers using origami-inspired manufacturing technology could significantly reduce the environmental impact of heavy transportation around the globe.

Swedish technology and design startup STILRIDE has created proprietary sustainable manufacturing technology, called STILFOLD, which involves the use of robotic arms to fold steel over curves to form light and strong new structures, using minimal component parts.

The technology is currently being used to build a fleet of sustainable steel electric motorbikes, reducing the environmental impact of EV production by as much as 50%.

But the firm also estimates that if used to build semi-trailers, STILFOLD could remove the need for approximately 360,000 HGV journeys to be made a year and prevent up to 12,000 tonnes of CO2 from entering the atmosphere, by increasing HGVs’ load capacity by 5% and making semi-trailers more efficient.

1. Design

To reach this estimate, STILRIDE's design team first worked out how they could build a semi trailer by folding sheets of steel over curves using STILFOLD, with the aim of decreasing the trailer's total weight and simplifying its construction.  In their design, they reimagined the traditional ladder frame used in semi trailers, instead creating an "origami" exoskeleton using origami-inspired steel folding. The outer shell is composed of two steel sheets with one main weld and eight, strategically-placed folds. This gives the necessary structure and keeps the weight down.

2. Performance

The STILRIDE designers focused on making their semi trailer more aerodynamic and improving its material efficiency to make it strong yet light. The STILFOLD trailer requires 90% fewer component parts (compared to traditional models) and can be constructed using 30% fewer materials. The STILFOLD trailer would weigh an estimated 2000kg less than traditional semi trailers, weighing in at 6000kg (compared to ~8000kg for existing models). The STILRIDE designers aimed to simplify elements of the design and use fewer materials whilst retaining the trailer's structural integrity; and to improve the trailer's performance to reduce HGVs’ fuel consumption whilst enabling HGVs to carry heavier loads.

3. Impact

To work out the impact their design could have, researchers analysed Swedish transportation data with a focus on the construction and mining sector.

Jonas Nyvang, CEO and co-founder at STILRIDE, comments:

"We are always looking for new ways to advance our STILFOLD technology and reduce the automotive industry's impact on the planet. Heavy goods transportation accounts for a significant proportion of transport emissions in Europe – and so it's an area we’ve long been interested in tackling.

"As this new research shows, our technology has the potential to significantly reduce HGVs’ impact on the planet, by rethinking how semi trailers are used and produced through innovative design. This use case shows that by embracing change and innovation, it is possible to transform how heavily polluting industries operate, improving performance and efficiency whilst reducing emissions.

"Our immediate focus remains on bringing our first electric motorbike to market – but in future we hope to bring innovations including a sustainable steel semi trailer to market."

Henrik Sieurin, Expert Engineer at Scania, whose PhD from KTH Royal Institute of Technology focused on steel and material optimisation, comments:

"Replacing the traditional ladder frame trailer with a STILFOLD structure enables aerodynamic improvements and reduced weight, offering reduced fuel consumption and increased load carrying capacity, reducing the environmental impact of heavy transport."

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