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Alpine: Vehicle Parts Made from Linen for Fully Electric Prototypes
Automobile manufacturer Alpine aims to further advance decarbonization by using sustainable raw materials, among other strategies, and thus uses linen for some parts of the fully electric prototype Alpine A110 E-ternité, which made its debut at the French Grand Prix in July 2022. Flax, the raw material for the natural fabric, grows near the Dieppe plant in Normandy.
"It was a technical challenge to transition from a conventional A110 with a combustion engine to the fully electric A110 E-ternité. The eco-conscious approach of using linen in a vehicle is a real opportunity for us. The material is lighter and marks a step forward both technologically and ecologically," said the Exterior Accessory Design Leader at Alpine.
Less Density, Less Energy in Production
According to the manufacturer, the Alpine A110 E-ternité's front hood, roof, rear cover, seat shells, and rear bumper are made of linen, which helps to save some weight. Despite having 392 kilograms of batteries, it weighs 1,378 kilograms, making it lighter than other electric models in this segment.
The carbon front hood of an A110 R weighs 3.98 kilograms, according to the manufacturer, whereas the standard A110 aluminum hood weighs 6.9 kilograms. However, a part made of linen currently weighs 20 percent more than a carbon element. Yet, it allows for a large number of functions to be integrated, and the number of parts can be reduced.
The flax comes from organic cultivation by the company Terre de Lin near Dieppe, the founding location of the Alpine brand. The production process is far less energy-intensive than that of carbon. In addition to the low density and low weight, the manufacturer also cites its resistance and acoustic properties as additional advantages.
From Seed to Automotive Component
But how does the raw product become a vehicle part? Sowing takes place in March and April, and harvesting of the plants happens in early summer. The long fibers are then combed, smoothed, stretched into yarn, and bundled into 45-kilogram bales, according to the manufacturer. In the spinning mill, the material is then woven into fabric and delivered to Alpine.
In the Alpine lab in Les Ulis, southwest of Paris, the dried fabric is finally combined with cotton yarn, and a 45-degree pattern is woven. According to the company, the fabric consists of 95 percent flax and five percent cotton and is then soaked in epoxy resin and molded into shape.
Great care must be taken with the alignment of the fabric as well as the number of creases. The outer, visible surface is brought into contact with the mold. The next step is to cover the part and treat it under vacuum. The prototype part is then removed from the mold, hand-trimmed, and assembled at the so-called Alpa' Innov Center.
Future Visions
Over time, the epoxy resin is also expected to be replaced in order to completely decarbonize the components, according to the plan. There is already a search for bio-based resins that meet the requirements. Many different options are being considered, including the development of flax shapes for manufacturing.
“We are considering making parts from carbon fiber, glass, or flax in the same form in the future. It is still too early to talk about the large-scale use of flax in series production at Alpine – but the initial tests look promising,” says the Exterior Accessory Design Leader.
What does it mean?
Alpine is increasingly working on its independence within the Renault Group – and can also serve as a "small series lab" here.
Translated automatically from German.
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