Recently, the RevolutionVLR project, in which TRBLightweightStructures UK participated, successfully developed a new passenger train that facilitates rail expansion and the reopening of old lines. TRB worked with the International Transportation Design Institute to design the train's composite bodyshell and create modular, one-piece structural panels for the vehicle's interior and exterior walls.
The goal of the RevolutionVLR project was to develop a lighter, more energy-efficient train structure that meets stringent rail safety standards and government decarbonization goals. To achieve this, TRB produced modular panels using carbon fiber laminates and recycled foam cores.
The project also used a unique polyfurfuryl alcohol (PFA) bio-resin, derived from sugarcane refining by-products, as the matrix for the composites, replacing traditional phenolic resins. Combined with advanced process technology, the project team created a modular demonstrator vehicle body that is up to 40% lighter than a conventional train body of the same volume. This weight reduction allows single-car vehicles to operate on reactivated old lines or new lines with lightweight infrastructure.
The modular panels not only reduce the weight of a single car by 16 tons, but also incorporate sustainable biomass materials, making a significant contribution to the decarbonisation of the UK transport sector.
