How sandwich panels drive innovation

With the introduction of 30 km/h speed limits across many European cities, urban mobility is undergoing a major transformation. More and more municipalities are looking for smart, sustainable solutions that can cut emissions and energy use, without compromising on safety or efficiency. In this context, aluminium sandwich panels are proving to be a truly strategic material.

The development of a 100% electric modular platform is a concrete example of how sandwich panels can enable applications that combine technological innovation with environmental responsibility.

The challenge

The goal was to design a universal load-bearing structure that was:

• lightweight, to extend electric range
• strong, to handle loads up to 500 kg and 3000 litres of volume
• and modular, to adapt to multiple configurations, all while keeping environmental impact to a minimum.

The solution: Compocel AL^®

To meet these requirements, the structure was built using Compocel AL^® aluminum sandwich panels, a solution that made it possible to achieve a light yet high-performance frame, delivering up to 100 km of electric range while maintaining outstanding rigidity and reducing overall energy consumption.

The combination of strength and modularity made it possible to develop [board]: a flexible base adaptable to a wide range of applications, from cargo transport to passenger services. Moreover, the use of recyclable aluminium ensures full alignment with a sustainable design philosophy, pushing innovation forward without overlooking environmental impact.

Why Compocel AL^® was chosen:

• Lightweight: reduces overall mass, improving energy efficiency.
• Mechanical strength: ensures stability and durability under heavy loads.
• Modularity and workability: easily adaptable to different platform designs.
• Sustainability: made from recyclable aluminium, consistent with the project’s green vision.

Tangible results

The outcome is a robust yet lightweight structure that enhances the vehicle’s overall performance. The range reached 100 km, while the top speed improved alongside a noticeable reduction in energy consumption.

Thanks to its modular and versatile nature, the platform can be tailored to various urban and logistic scenarios, opening new possibilities for sustainable mobility. But it’s not just about performance: the fusion of technology and sustainability has turned [board] into a tangible example of cleaner, more efficient urban electric mobility.

Conclusion

Credit goes to the One Board team, who brought together design, engineering and sustainability to turn this vision into a real, innovative urban mobility solution. 

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This project demonstrates that sandwich panels are not just a material, but drivers of innovation, enabling the creation of a modular electric platform that marks a decisive step forward for the cities of tomorrow: lighter, more efficient, and more sustainable.