Constellium - ALIVE

Core Competitions

Aluminium Intensive Vehicle Enclosures

Project Highlights 

  • Novel enclosure architectures that will provide scalable design and manufacturing concepts utilising agile multi-platform cells on the same production equipment, engineered to meet variable volume demands, while providing a kit of parts for local assembly and export options. 
  • Project will design, develop, assemble and extensively test aluminium intensive prototype enclosures and full-scale demonstrator enclosures for BMW and Volvo electric vehicles, forming an integrated pathway to UK battery pack production by providing the light weight enclosures aligned to current and future battery module technologies and power densities. 
  • The total project value is £15.3 million, with £7.5 million funded through the APC. 

Project Consortium 

  • Constellium 
  • BMW  
  • Brunel University 
  • Expert 
  • Innoval Technology 
  • Powdertech Surface Science 
  • Volvo 
  • Warwick Manufacturing Group 

Establishing a UK based manufacturing facility

The project aims to take another major step with disruptive high strength aluminium alloys and their processing and joining technologies, enabling new enclosure design concepts for the manufacture of both vehicle integration structures and battery enclosures for a new generation of lightweight hybrid and electric vehicles for the UK market that will have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet. The project will establish a UK based manufacturing facility for world leading cost-efficient structural aluminium battery enclosures providing an on-shore resource for BEV and PHEV component manufacture, with the manufacturing concept capable of providing efficient transportation of parts for export assembly.
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