SAFEFOLD: Implementation of Origami technology for industrial application

Purpose and goal

The aim is to physically verify STILFOLD´s tool-free, software-defined folding technology in a safety-critical vehicle structure – from digital potential to industrial proof. The goal is to develop and manufacture a pilot series of 50 Front Cross Members, with Volvo Cars, evaluate them against real eligibility requirements on function, manufacturability and vehicle integration, and move the technology from TRL 6 to TRL 7 with a verified decision basis for continued industrialization.

Expected effects and result

SAFEFOLD delivers a basis for continued industrialization for Volvo Cars against requirements on function, manufacturability and vehicle integration. The technology is moved from TRL 6 to TRL 7 and the collaboration from BRL 6 to BRL 7. In terms of effect, material waste, number of parts and the need for tools are reduced. This results in lower embedded CO₂ per component and a shortened development time. Industrial resilience increases through reduced dependence on global tool suppliers.

Planned approach and implementation

The project is being run in four work packages over 12 months. AP1 Kravdefinition (Volvo Cars): Criterias are set established as a common data basis. AP2 Designprogrammering (STILFOLD): the requirements are translated into folding geometry through two design loops with Volvo Cars CAE- and crash expertise. AP3 Pilotserie (STILFOLD): 50 copies are manufactured with part production assessment and measurement protocol. AP4 Utvärdering (Volvo Cars): industrial test, final report and decision basis.