OPTIBEV: Technology for faster development of lighter, stronger components for electrified heavy vehicles

Purpose and goal

Integrera STILFOLDs tool-free, software-controlled sheet metal bending in Volvo Bus development flow for lighter, stronger and more circular structures. Results/effects: validated prototypes, movement TRL 5→7 and BRL 5→6, lower material consumption and component complexity and an implementation plan. Approach/implementation: iterative digital design in STILWARE is combined with Volvo Bus CAE analysis and physical prototyping that links simulation to practical validation.

Expected effects and result

The project delivers validated physical prototypes of folded sheet metal structures and moves the solutions to TRL 7 and BRL 6. The results show lighter and stronger components with higher material utilization, lower complexity and eliminated tooling investment. The structures become easier to dismantle and recycle, which strengthens circularity. In the long term: faster development cycles, lower cost and CO2 and a validated method and implementation plan for industrialization at Volvo Bus.

Planned approach and implementation

The work is divided into 4 phases. 1) Component selection and requirements: Volvo defines functional requirements, packaging and load cases. 2) Digital design: STILFOLD generates and optimizes folded structures iteratively. 3) Verification: Volvo evaluates performance and durability via CAE; the design is iterated against the requirements. 4) Prototype and validation: structures are manufactured and tested. Working methods are documented and an implementation plan is developed.