Alstom has announced an expanded collaboration with Swedish technology start-up Stilfold to further explore innovative steel-forming solutions for rail applications. Building on the successful completion of a pilot programme, the two companies will now assess how Stilfold’s distinctive curve-bending technology can be applied to a broader range of train components and structural elements.
Stilfold’s patented method reshapes flat steel sheets through a controlled folding and bending process inspired by origami principles. Instead of relying on conventional heavy fabrication and extensive welding, the approach forms strong, lightweight structures through precision shaping. The technology presents new opportunities for component design while supporting ambitions to lower material use, energy consumption and overall production costs.
During the pilot phase, Alstom evaluated the structural performance and manufacturing feasibility of selected components produced using Stilfold’s process. The results confirmed that the method offers considerable promise for rail manufacturing, combining durability with improved material efficiency.
Ganesh Chandramouli, Head of Innovation, Strategy and Product Portfolio at Alstom Sweden, stated that the pilot outcomes have demonstrated significant potential across multiple train applications. He noted that advancing the collaboration will allow both companies to identify solutions that contribute to reduced environmental impact while enhancing cost competitiveness.
Compared with traditional fabrication methods, Stilfold-based structures require less raw steel and fewer energy-intensive processes such as welding. The streamlined production sequence lowers associated emissions and resource consumption. Despite the reduced material input, the shaping technique can enhance structural integrity, enabling components to maintain or even exceed required strength standards. Additionally, the lighter weight of such structures can support improved energy efficiency in train operations.
Jonas Nyvang, Co-founder and Chief Executive Officer of Stilfold, said the progression from pilot to expanded evaluation marks an important milestone for the company. He highlighted that industrial validation with a global rail leader demonstrates the capability of the technology to transform how steel components are engineered and manufactured.
In the next stage of cooperation, engineers from both organisations will analyse existing train components to determine where the curve-bending method can deliver the greatest benefits. Areas of focus will include weight reduction, simplified assembly processes and measurable climate impact improvements.
Innovation remains central to Alstom’s strategy to enhance sustainability and operational performance. Through initiatives such as its Innovation Station in Sweden and partnerships with universities, research institutions and emerging technology firms, Alstom continues to foster a collaborative ecosystem aimed at shaping the future of environmentally responsible rail transport across Europe and beyond.
