Constellium is proud to announce the successful completion and publication of the FlexCAR project, its latest innovation effort with ARENA2036, Germany’s leading research campus for future mobility and production technologies.
The FlexCAR platform envisions a future where major vehicle systems — such as the drivetrain, energy storage, and interior — can be easily configured or updated. Constellium worked alongside project partners such as Mercedes-Benz, Siemens, Bosch, and the German Aerospace Center (DLR) to complete this publicly funded, five-year project.
To help ensure that the structural backbone of this open architecture meets the highest standards in safety and performance, Constellium developed a modular sill concept using aluminium extrusions made from Constellium HSA6™ high-strength aluminium alloys featuring significant recycled content. Designed to support various powertrains — including battery electric and hydrogen fuel cell—the sill structure offers enhanced crash performance, design flexibility, and a lower carbon footprint over the vehicle’s lifecycle.
“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,” said Patrick Böhler, Director of Sales & Product Development for Constellium Automotive Structures. “Collaborations like these are how we turn ideas into real-world innovations.”
Constellium also previously collaborated with ARENA2036 on the Digital Fingerprint innovation project, developing a digital twin of an aluminium component that tracks its performance across its full lifecycle — from design and production to on-road use and end-of-life. As part of this project, completed in 2024, Constellium engineered a smart aluminium housing for a power control unit, embedding sensors to collect crash and field data in a Mercedes-Benz test vehicle. This approach supports predictive maintenance, accelerates development cycles, and unlocks the full potential of connected, data-driven manufacturing.
Constellium is a full-service supplier of rolled and extrusion-based aluminum solutions for the global automotive market. We help automakers produce lighter, safer, and more fuel-efficient vehicles, as well as electric vehicles with greater range.
Note: This article has been issued by Constellium and has been published by AL Circle with its original information without any modifications or edits to the core subject/data.
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