Morris All Carbon Electric (MACE)
The MACE (Morris All Carbon Electric) project builds upon previous successful feasibility study and proof of concept research projects to deliver an ultra-lightweight solution for producing complex, feature rich load bearing structural panels reinforced with recycled carbon fibre.
Project Overview
The aim of the project was to further develop the materials and production processes for cost effectively manufacturing panels capable of being used in structural and semi-structural applications. Recycled carbon fibre was used to build the body upper structure – including closures – to significantly lightweight the vehicle, in turn improving the EV range.
Technology
Utilising prepreg recycled carbon fibre (RCF), supplied by Gen 2 Carbon, Prodrive Composites supported Morris with design and manufacturing advice for moulded panels and structures using RCF. Morris developed digitalising methods to predict the weight and body requirements so that different structural requirements could be created according to RCF properties, which enabled the partners to optimise the layup. Together, the project partners have developed a unique construction method using RCF in a monocoque body style which enables a modular style construction.
Significant project outcomes
The project has accelerated not only the development of the product, but also in facilitating further investment from Morris and commitment to the project. As a result of the NVN funded projects, Morris have been able to trial and further develop inner structure and assembly processes, and it has enabled them to validate the packaging and other components. The project has successfully demonstrated the technical viability of RCF prepreg for manufacture of complete body structures.
Primary route to market
The project’s primary route to market is the Morris light commercial vehicle, which is a 2.5-ton GVW vehicle with a 1-ton payload and 250-mile range. The increased payload and extended range compared to existing EV commercial vehicles on the market has led to significant pre-launch interest from a range of potential fleet and private individual customers.
Securing funding support from NVN built confidence with Morris Commercial shareholders and enabled further investment, facilitating development activities from Morris which would not have been feasible without the confidence created through the NVN funding stream. The project deadlines enforce project partners to respond to tight timescales which helps accelerate development work, as well as facilitating engagement with suppliers.
- Dr Qu Li, CEO – Morris Commercial