LEVA Project launches at BCAST in partnership with Lotus

LEVA Project

In partnership with Lotus and Sarginsons, BCAST at Brunel University London has launched project LEVA to accelerate innovation and development of lightweight structures for electric vehicles (EVs). The LEVA project – Lightweight Electric Vehicle Architecture – will aim to accelerate innovation in the development of lightweight structures for EVs, acting as a showcase for new, cutting-edge chassis and powertrain concepts.

Incorporating cutting-edge UK-based engineering and manufacturing expertise, LEVA will be a showcase for pioneering new BEV chassis and powertrain concepts. Lotus will collaborate with supply chain partner Sarginsons in the development of a state-of-the-art digital twin, adopting high-performance aluminium alloys developed by leading academics from BCAST at Brunel University London. 

“The alloy won a national innovation award in 2017 because of its high strength and ductility,” said Prof Shouxun Ji, a professor in materials at BCAST.

“I hope we can now use it to help UK industry realise their goals in advancing automotive manufacturing technology.”

Funding for the project will come as part of the Advanced Propulsion Centre’s (APC) Advanced Route to Market Demonstrator competition, which was delivered on behalf of the APC by Cenex, the UK’s Low Carbon and Fuel Cells Centre of Excellence.

Matt Windle, Executive Director of Engineering at Lotus, said: “As a collaboration between Lotus, Sarginsons Industries and Brunel University London there is a wealth of talent involved, and we are excited to have already begun the project work.

“Following the launch of the Lotus Evija, our all-electric 2,000 PS hypercar, this project is a key building block in our vision to deliver a full range of electrified Lotus performance cars ‘For The Drivers’. Funding of this nature is critical to stimulate the automotive industry and supply chain as both continue to adjust to a rapidly changing landscape.”

Lotus have identified key enablers for the development of a series of new, UK BEV products, scalable from an ‘every-day’ BEV sports car up to a sports cross-over. The BEV products could integrate into an existing ‘in-development’ platform based upon the world-renowned Lotus aluminium bonded chassis. This opportunity is not currently within the Lotus’ Vision 80 cycle plan, and project LEVA would spearhead new, incremental Lotus BEV sports cars and client products, dramatically increasing the number of UK manufactured BEV products and positioning the UK as leaders in BEV lightweighting. The technical project outputs will include; digital vehicle concepts, a multidisciplinary optimisation model (Digital Twin), and a state-of-the-art prototype, lightweight rear sub-frame for a rear electric axle. This lightweight frame will encompass a patented die casting alloy recently developed by leading academics at Brunel University London. Casting prototypes and key aspects of the digital twin development will be led by SME manufacturer Sarginsons. The total project budget is £1.99M and the APC grant requested is £1.0M. The project outcomes have a clear route to market with opportunities which can lead to new job creation within the OEM and supply chain, underpinned by new, UK-based BEV production and leveraging UK IP.