The List-P project led by Omnia and supported by Tata Technologies, Arrival, Polymer Industries, Foresight Innovations, the National Composite Centre and the University of Exeter is investigating the development of a novel lightweight composite sandwich panel for medium and heavy goods as well as passenger vehicles. These will ultimately improve operational efficiency and help towards the delivery of zero emissions, as well as reshoring manufacturing capacity and capabilities to the UK. Omnia are specialists in delivering new material solutions and intelligent products. Its focus is on thermoplastic panel technology and the supply of its unique range of composite sandwich panels. These not only offer excellent strength to weight characteristics, but also durability, innovation and sustainability. Over the last decade Omnia has provided its customers with intelligent solutions based on sound engineering, economic and socio-economic principles. Some of its clients include, PepsiCo International, Williams F1, BP, Northgate Group, Royal Mail, DHL and TNT. The List-P project brings together experts from across the supply chain in order to provide an end-to-end solution and optimise design and manufacture of future automotive panels.

Power electronics is an enabling technology that is critical to the successful emergence of electric and hybrid vehicles. Common building blocks of miniaturised smart power elements, which can accommodate conventional or wide bandgap semiconductors and control electronics, will be required to meet a range of applications in electric and hybrid vehicles, including the generation, conversion and distribution of electricity around the vehicle. In parallel, with the impetus to produce lighter vehicles, designers are considering the use of thermoplastic composites within the vehicle structure. In this feasibility study, a performance comparison will be made between a power module manufactured using the new electronic packaging technology and embedded in a composite structure, to a module manufactured and packaged using conventional technology. The comparative assessment will include electrical performance, size and weight, and through-life costs.

The project will investigate novel methods of welding future lightweight automotive structures. In particular, the project will consider new methods of Friction Stir Welding to join automotive body structures made of novel lightweight alloys including aluminium, high strength steel and magnesium. The aim is to demonstrate high strength joints by doping the weld with different grades and concentrations of additives which may positively influence the structure of the material in the weld and improve strength. The work builds on existing UK expertise, with the Friction Stir Welding process invented in the UK by The Welding Institute. The new processes will ultimately gives rise to a more durable, stronger and/or lighter joint. The process can also be readily used to join difficult and/or dissimilar lightweight materials of high promise.

The aim is to undertake systems analysis of a new integrated heat recovery concept for future hybrid and electric range extender passenger cars. The proposed work is multidisciplinary in nature, including fundamental R&D of novel thermal coatings, quantification of ICE performance effects, exhaust heat recovery analysis and electric motor & battery performance analysis. The approach involves the use of new thermal barrier coatings that can reduce ICE wall heat losses by 30%. The premise is based upon minimising the heat lost to the engine coolant/oil and elevating the gas temperatures in the exhaust, where the energy can be more easily recovered. The method is particularly well suited to future hybrid and electric range extender applications, where knocking combustion can be more easily avoided and rapid catalyst light-off achieved. The work involves study of innovative technology in three areas. 1. Materials and manufacturing R&D of novel thermal surface coating technologies. 2. Evaluation of the effects of the coatings on ICE performance, fuel economy and emissions. 3. Analysis of the performance of the coatings when combined with exhaust heat recovery, hybrid and electric range extender powertrain technologies.