Constellium has completed its smart aluminium automotive project FlexCAR.
FlexCAR was carried out alongside Germany’s leading research campus for mobility technologies, Active Research Environment for the Next Generation of Automobiles (ARENA2036).
The publicly funded, five-year project was developed alongside partners such as Mercedes-Benz, Siemens, Bosch and the German Aerospace Centre (DLR).
The FlexCAR contains a modular sill concept using aluminium extrusions made from Constellium HSA6 high-strength aluminium alloys which are partially recycled.
The sill structure offers enhanced crash performance, design flexibility and a lower carbon footprint.
Director of Sales & Product Development for Constellium Automotive Structures, Patrick Böhler, stated: “FlexCAR shows how modular thinking—combined with the performance and sustainability benefits of aluminium—can revolutionise vehicle design, enabling longer lifespans, greater adaptability, and lower environmental impact.
“Collaborations like these are how we turn ideas into real-world innovations.”
Constellium and ARENA2036 have previously worked together on the Digital Fingerprint project to develop a digital twin of an aluminium component that tracks its performance across its lifecycle.
Since 2018, Constellium has been a contributor to ARENA 2036, a German research platform for mobility and production technologies.
