Lightweight Composite Rail Door

The Approach

The team executed an intensive research and development phase to conceptualise the initial project design, utilising 37% fewer components and a mass reduction of 10kg. The use of carbon fibre with polymer resin core enabled efficient press forming to streamline the manufacturing process.

Following virtual testing, the engineering team commenced the build phase, fabricating a lightweight composite door that underwent rigorous testing, including over 1,000,000 dynamic cycles, surpassing static and dynamic test requirements. Additional testing was conducted to meet industry safety standards for public safety.

The integrated design featured an optimised window system for enhanced maintenance ease, improving service times. Overall, the design enhancements improved durability, reduced track wear and extended the service life of the door leaf assembly by up to 40 years.

The team rose to the challenge and began the intense research and development phase of the technical design, using state of the art software.  The design was created using 37% fewer components than the original and achieved a mass saving of at least 10kg.  Once the design had been virtually tested, the engineering team initiated the intricate build phase.

Utilising carbon fibre with an impregnated core of polymer resins, creates a malleable sheet which is easy to press form using a modern hydraulic press.  The lightweight composite door was rigorously tested, undergoing over 1,000,000 dynamic cycles, where its performance exceeded the static and dynamic test requirements.

The blueprint integrated an optimised window system design enabling ease of maintenance, and therefore improving service times.  The whole design improved durability, reduced track wear and extended the service life of the door leaf assembly by up to 40 years.