The revolution in the automotive world in recent years, with the move to electric vehicles, emphasis on recycling, reduced CO2, sustainability and zero emissions, has demanded significant lightweighting action in the body-in-white arena.”   Bob Mustard, CEO, Stalcom Automotive Technologies

Low Tooling Cost & Investment


High Strength

Tough & Damage Resistant


Fast Prototyping Process

Good Crash Performance

NVH Benefits


Flex-tech is an interlocking thin-wall extrusion system designed and developed by Stalcom. It is made from aluminium and composite, making it both lightweight and strong. Flex-tech allows spaceframe structures to be created quickly and easily at minimal cost, eliminating the need for expensive tooling. These attributes make it ideal for vehicle primary structures.

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A safety tested, scalable, fully programmable platform for niche vehicles which is both affordable by requiring minimal tooling.  Stalcom’s EV skateboard using FVA is a way to offer cost effective solutions to the niche vehicle sector.

  • No model specific form tooling
  • Changes in design, shape and dimension are fully programmable
  • Flexible for fwd and rwd, front or rear drivetrain, (from a common suite of parts)
  • Scalable platform can be applied to a whole variety of niche vehicles
  • Lighter, safer, greener and more cost-effective
  • Performance and economy are potentially better than a design adapted from a conventional vehicle


Inspired by the aerospace industry, the body structure by LEVC electric van is made from lightweight, bonded aluminium, which, once hot cured, provides over twice the tensile strength of a welded equivalent, and absorbs twice the crash energy of mild steel - so occupants and structural components are better protected in the event of a future collision. The body structure also benefits from an estimated weight saving of 30%, compared to a steel equivalent, which means better handling and improved economy.

All of the aluminium body is anodised to ensure consistent adhesive bond strength while maintaining high levels of corrosion performance. It is also 100% recyclable – further improving the vehicle’s environmental impact.

Bob Mustard was part of the team that worked on delivering this project. Learn more about the VN5 Electric Van |


Using the Powderbond joining process, Stalcom carried out a feasibility study examining the creation of a lightweight hybrid material for an HV battery box.  The result of this study was the creation of StalcomLightweight Laminate .The hybrid box exhibited improved puncture resistance to conventional enclosures with a significant weight saving whilst retaining the EMC shield of an all metal design


Product and process design is at the heart of Stalcom Automotive Technologies. Design optimisation with extensive use of FEA is key but also by proposing and designing for the manufacturing processes appropriate for the proposed manufacturing volume. Stalcom works with clients to deliver effective and efficient structures. These have ranged from whole vehicle primary structures to seat frames, closures and complete BIW. Prototypes are produced and testing is completed.