Project Mobius develops AI-powered digital toolkits to optimise car body structures for whole-life sustainability and cost. **Problem** After batteries, bodies are the biggest source of 'point-of-sale' CO_2e_ emissions, mostly driven by material production. Today, car bodies are not explicitly optimised for CO_2e_, only 50% of input material is utilised and most high-grade materials are downcycled at end-of-life. **Solution and impact** We will develop digital tools and net-zero enabling technology for designers to lock-in materially efficient decisions early in the vehicle development process reducing body structure emissions by 75% whilst reducing timescales and boosting cost competitiveness, aligning with UK sustainability strategy.

The project is to fund DeepForm Limited's first prototype product: a novel die-set for stamping a car body structural part with less waste, cost and embodied emissions. Almost half of sheet metal purchased for making car body parts globally is trimmed off and scrapped, adding almost 10% to the embodied emissions of every vehicle. DeepForm Limited, a spin-out company from University of Cambridge has access to a novel, patent pending stamping die concept 'DeepForm' that that promises a 75% reduction in scrap, a 20% reduction in piece price, and the opportunity to make parts with stronger material grades. In this project, we will construct and evaluate a production-ready die set to manufacture a part in current production at an automotive OEM. The die will be fabricated by UK-based SME and die manufacturer, Whiston Industries, and a production run of up to 100 parts will be carried out. This project will kickstart DeepForm Limited as a UK business aiming to reduce the embodied emissions of car production.