STEEL-ALIVE – STEEL Applications for Low Investment manufacturing of high Value Elements – is a new European research and innovation action in which IFEVS joins forces with leading industrial and academic partners to redefine how advanced high‑strength steel (AHSS) is formed and assembled for light commercial vehicles (LCVs).

The project’s overarching goal is to create a flexible, sustainable and economically viable production ecosystem that aligns with the EU Green Deal while accelerating electric‑vehicle adoption. By starting from standard AHSS tubes and flat sheets that are cut, folded, punched and welded—instead of stamped or giga‑cast—STEEL‑ALIVE will:

  • reduce upfront tooling investment by 80 %;
  • cut energy demand and CO₂ footprint during part manufacture by 70 %;
  • lower production cost by 30 %; and
  • halve time‑to‑market.

Key technology streams include high‑accuracy laser cutting, adaptive bending & punching of tubes, and advanced welding processes. Multi‑scale material characterisation feeds into simulation models that predict structural behaviour at both component and vehicle levels.

Beyond hardware, the consortium will publish guidelines, training modules and certification programs for joining AHSS, benefitting the wider European steel sector.

Three representative demonstrators will showcase the approach: a battery case, a rear carrier box and a space‑frame body for LCVs. All are designed to eliminate expensive dies, presses and robotised assembly cells, proving that innovative steel solutions can be manufactured cost‑effectively in Europe.

Consortium

The project is coordinated by FUNDACION CIDAUT and brings together:

  • BELGISCH INSTITUUT VOOR LASTECHNIEK VZW INSTITUT BELGE DE LA SOUDURE (BE)
  • IFEVS – Interactive Fully Electrical Vehicles srl (IT)
  • ArcelorMittal Maizières Research (FR)
  • PRIMA INDUSTRIE SPA (IT)
  • Centro Ricerche FIAT SCPA (IT)
  • StreetScooter GmbH (DE)

IFEVS will contribute its vehicle integration expertise, validating that the new AHSS components meet safety, weight, and cost targets for fully electric delivery vans.

STEEL‑ALIVE is currently active; further updates will follow as the project reaches its first technology milestones.