Structural Optimisation Using Light Metals andAffordable Composites for the Ariel Hipercar.

Stalcom Automotive Technologies was a key contributor to this R&D project supported by the Niche Vehicle Network. Other partners included Ariel Motor Co, Babcock and Powdertech. With support from the Niche Vehicle Network and the Advanced Propulsion Centre, Stalcom conceived the SOLMAC project. Delivered in partnership with Ariel, Powdertech and Babcock, the project had two phases. 

PHASE 1

This design approach combines the best properties of both aluminium and composites to deliver significant product and commercial benefits.
  • New production technique using bonded aluminium structures
  • Curing complex vehicle chassis structures using a conventional overhead conveyor and powdercoating oven.
  • Applying a protective and decorative powdercoat with one common cure cycle

PHASE 2

  • Produced large sub-assemblies by moulding affordable, high-performance composites
  • Developed joints between the aluminium and composite using a specially developed surface pre-treatment
  • Proved the joints were significantly stronger than the best adhesive system.
  • This breakthrough process has been renamed PowderbondPP.
Stalcom has developed significant know-how in both the design and process aspects of this approach which can now be applied to new projects.

Stalcom has developed significant know-how in both the design and process aspects of this approach which can now be applied to new projects.