“Industrial origami” manufacturing technology could make heavy transportation greener

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.

Methodology

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.

• The data shows that in Sweden, 44 million journeys are made by HGVs annually, with over 492 million tonnes of goods being transported over 3.4 billion kilometres. A large proportion of these journeys are short and involve supplying the construction and mining sector with materials and resources. These journeys account for 33% (161.5 million tonnes) of the freight transported within Sweden each year.

• The mining and construction sector has an average 22 tonne maximum load limit for each journey. Assuming that at least 50% of all journeys are made using a HGV or LGV (Large Goods Vehicle) with a trailer attached, and 60 - 70% of the load capacity is enabled by the trailer, STILRIDE calculates that around 48 million tonnes of material are being transported by trailer in the mining and construction sector annually.

• The STILFOLD trailer is two tonnes lighter than the semi trailers currently in use. If just 50% of the 7,346,000 yearly journeys within the mining and construction sector gained 2 tonnes of load capacity each year, this would create a load increase of 7,346,000 tonnes which represents 5% of the total yearly tonnage transported within the mining and construction sector in Sweden.

• STILRIDE researchers estimate this load increase could mean 360,000 heavy load journeys could be prevented each year, preventing 12,000 tonnes of CO2-eq from entering the atmosphere annually.

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.”

Methodology

• In Sweden, 44 million journeys are made by HGVs annually, with over 492 million tonnes of goods being transported over 3.4 billion kilometres. A large proportion of these journeys are short and involve supplying the construction and mining sector with materials and resources. These journeys account for 33% (161.5 million tonnes) of the freight transported within Sweden each year.
• We can assume that almost all journeys in the mining and construction sector are weight-driven, meaning the maximum possible weight of the complete truck load is reached. The potential weight savings on a semi-trailer chassis will be proportional to the allowed maximum load weight of the vehicle.  
• We know that the mining and construction sector has an average 22 tonne maximum load for each journey - and the sector often relies on shorter HGV journeys. We assume that 50% of all journeys are made using a truck or HGV with a trailer attached to reach a higher load capacity. 60 - 70% of the load capacity is enabled by the trailer.
• Therefore the total yearly trailer transport within this sector is 161,524,000 x 0.5 (factor with trailer) x 0.6 (factor of load at trailer) = 48,457,200 tonnes.
• With the STILFOLD designed semi trailer, we estimate an increased trailer load capacity of 2 tonnes by reducing the weight of the trailer itself. This will lead to a 5% increase in load capacity for weight-driven transports overall, and a reduction in the number of journeys needed. We estimate that the increased load capacity driven by our lighter and stronger trailer would mean over 360,000 journeys could be prevented annually.
• This is because: if 50% of the 7,346,000 yearly journeys within this sector gain 2 tonnes load capacity it gives an increase of 7,346,000 tonnes, which is a capacity increase of 5% of the total yearly tonnage. This represents up to 360,000 journeys made to transport mining and construction material in Sweden annually. This equates to around 12,000 tons of CO2 eq in reduced climate footprint. And this is only for the construction and mining sector. The CPP calculation: 4,435,000 tonne km x 5% reduction factor = 221,750 tonne km x 52.7g/km Co2 eq* = 12,000 tonne CO2 in CPP annually.

References 

• Trafikanalys - Swedish road goods transport - The statistics on road freight describe traffic and shipments involving Swedish-registered lorries both within Sweden and abroad
• T&E Analysis of the CO2 emissions from heavy duty vehicles during the reference period (July 1st 2019 to June 30th 2020), published by the EEA in June 2021 https://www.transportenvironment.org/wp-content/uploads/2021/10/202108_truck_CO2_report_final.pdf

• CPP – Definition of Climate Performance Potential - https://visevic.medium.com/how-to-measure-the-climate-performance-potential-of-startups-6cc7fdb4110f

This report was produced in collaboration with Remanufaktur 2050 AB, an eco-design and circular design consultancy.

For more information and assets contact amy@crestcomms.com / 07943 033 173

Jonas Nyvang
CEO
+46707663022
jonas@stilride.com

STILRIDE is a Swedish technology and design company that will soon launch its first product, the electric motorcycle SUS1. SUS1 is also the first product to take advantage of the company's own and unique manufacturing process STILFOLD, where an origami-style process is utilized to shape advanced constructions from sheets of steel. The process not only creates extremely durable constructions, but also enables environmentally friendly and local production. STILRIDE was founded in 2020 by Tue Beijer and Jonas Nyvang.