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Emerald’s Body Structures engineering team have extensive experience in:

  • Design and Development of Multi-materials lightweight Body Structures including Aluminium and carbon fibre
  • Design, development and delivery of unique platforms and ‘top-hats’ for low investment manufacturing processes
  • Full lifecycle development of hot cure bonded aluminium structures using a mix of low cost aluminium extrusion, pressed and folded components

The team is focused on key attributes of body structure design:

  • Designed for lightweight and strength to exceed performance requirements
  • Adaptable design, manufacturing and tooling strategy based on specific business case and production volumes
  • Development of vehicles that meet the highest industry standards for performance – e.g. NCAP
  • Fast to market programme development – e.g. taking the TX from concept to production in 30 months
  • The teamwork between the Body Engineering and Manufacturing teams ensure a fully integrated approach

Capabilities and Experience

EAD has an industry leading team with full design lifecycle expertise in:

  • Digitally defining and evaluating all the primary concepts
  • Using extensive simulation to deliver a higher proportion of ‘right first time’ designs
  • Leading component testing for the body structures key processes and technologies
  • Defining the full vehicle testing requirement to industry extreme limits
  • Implementation of body structures using a combination of in-house knowhow and selected new technology
  • R&D activities on joining and pretreatments, and production integration with a range of industry partners



Emerald’s team has delivered three complete new vehicle architectures:

  • t-001 van project used a custom-designed body structure frame optimised for one-off prototypes of very high integrity
  • TX eCity structure was designed around a unique set of vehicle requirements and has been fully developed for series production
    • Low tooling and facilities investment
    • Crash performance equivalent to the highest standards in the industry
    • Flexible architecture for adaption for light commercial van
  • 35DV used a custom structure designed for multiple powertrain options. Designed, built and supplied within 12 months, and successfully completed arduous customer durability trials