HIDRIA has recently joined the FlexCrash project which is developing a flexible hybrid manufacturing technology that integrates additive manufacturing of surface patterns onto preformed aluminium parts. This European project focuses on aluminium alloys as the preferred material due to their lightweight properties, recyclability, cost advantages, and contribution to environmental sustainability.
The project aims to design new crash-tolerant structures capable of withstanding a wide range of impact conditions. A front-end structure has been selected as the demonstrator, addressing the fact that frontal collisions represent around 70% of real-world crashes. The hybrid manufacturing approach offers tailored mechanical properties, enabling safer, more adaptable structures while simplifying supply chains and reducing manufacturing costs by up to 20%.
HIDRIA contributes with its expertise in High-Pressure Die Casting (HPDC), enabling the precise and efficient production of the front-end demonstrator. The company’s use of green aluminium also reinforces the project’s environmental goals, supporting the EU’s strategy for zero-emission mobility.
A key ambition of FlexCrash is to demonstrate that HPDC can be applied to larger and more complex automotive crash structures, extending beyond its traditional applications. The project envisions vehicle structures with up to 20% weight reduction and significant safety benefits, potentially cutting injuries and fatalities by half.
This September, the FlexCrash project’s consortium held its latest General Assembly at HIDRIA’s facilities in Koper (Slovenia), sharing the latest updates and achievements on the project’s progress, and outlining the next steps.
