Rail manufacturer Alstom and Swedish start-up Stilfold deepen collaboration to explore advanced steel-forming technologies for rail applications.
The companies have expanded their partnership following a successful pilot programme that evaluated Stilfold’s curve-bending technology for manufacturing train components. The next phase will assess broader applications of the method, focusing on structural elements that could benefit from lightweight and material-efficient design.
Stilfold’s technology reshapes flat steel sheets using precision folding and bending inspired by origami principles. Unlike traditional fabrication methods that rely on extensive welding and heavy material use, the approach creates strong structures with reduced raw steel input. This technique aims to lower energy consumption during production and reduce material waste while maintaining structural durability.
Results from the pilot phase indicated that components produced with the curve-bending method demonstrated promising structural performance and manufacturing feasibility. The findings suggest opportunities to integrate the technology into rail manufacturing in ways that could enhance sustainability and cost efficiency.
According to innovation leadership at the rail manufacturer, the pilot outcomes revealed significant potential for multiple train applications. Further cooperation will explore solutions that reduce environmental impact while supporting competitive production processes.
Compared with conventional fabrication, the Stilfold method requires fewer energy-intensive processes such as welding and uses less raw steel. These efficiencies can contribute to lower emissions and resource consumption. Despite reduced material input, the shaping technique can maintain or enhance structural strength, supporting operational performance while improving energy efficiency through lighter components.
The progression from pilot testing to expanded evaluation marks an important step for the technology provider, as noted by its leadership. Industrial validation with a global rail company signals confidence in the technology’s potential to transform steel component engineering and manufacturing.
In the coming phase, engineers from both organisations will examine existing train components to identify opportunities where the curve-bending approach can deliver benefits such as weight reduction, simplified assembly and environmental performance improvements. Key areas of analysis will focus on operational efficiency and sustainable design outcomes.
