Sustainable logistics through lightweight construction

The project developed prototypes for lighter, partially self-supporting fairings for velomobiles and (food) transport boxes for transport bikes, so-called cargo bikes. The partner consortium, consisting of Cargo Cycling, Nijland Cycling, Niederrhein University of Applied Sciences, Saxion University of Applied Sciences and Netzwerk Oberfläche NRW (lead partner), aims to make a contribution to sustainability and in particular to climate-neutral mobility, as the cargo bikes enable_CO2-neutral logistics over short distances, among other things.

The project was based on the Fleximould developed as part of the Smart project. This is a flexible thermoforming tool located at the Niederrhein University of Applied Sciences, which was used for the first time for a specific application in the Fairing Flex project. The advantages of this flexible technology lie in its rapid prototyping. In addition, it is not necessary to build a separate tool for each mold, as individually automatically adjustable pins are responsible for shaping. This means that each mold is simply saved as a CAD file.

The pin tool consists of approx. 30,000 pins measuring 1600 x 600 mm. Each individual pin can be adjusted up to 300 mm in height. Resetting and resetting a mold takes up to 12 hours and can be done overnight. During the day, deep-drawn parts can then be produced in series or in batch size 1 with normal cycle times. Sharp-edged structures can be produced using additively manufactured inserts. The components, which had previously been unstable, were reinforced with carbon fiber laminates from Saxion University. The stability tests of the manufactured objects also take place here.

Another aim of the consortium was to focus as much as possible on sustainable and circular business practices. Sustainable materials were used wherever possible and concepts for taking back, repairing, reusing or recycling the individual components were developed.

Those interested in products or processes can contact the companies directly or contact the Netzwerk Oberfläche NRW.

The Fairing Flex project is co-financed by the European Regional Development Fund (ERDF), the Ministry of Economic Affairs, Industry, Climate Protection and Energy of the State of NRW (MWIKE NRW), the Ministerie van Economische Zaken en Klimaat and the Provincie Overijssel as part of the INTERREG program Germany-Nederland.