This thesis explores the use of lightweight composite materials in road freight trailer design as a means of reducing the emissions of the road freight industry. A comprehensive review of previous lightweight composite trailers and related projects was conducted; it concluded that the application of composites in trailers to-date has largely been limited by relatively high material and production costs. The review highlighted that the trailer industry could learn from the success of composites in the bridge construction industry. A statistical weight analysis of two road freight fleets and an energy consumption estimation, via a drive cycle analysis, were used to identify trailers that are particularly suited to lightweighting. Hardwood trailer decking was identified as a prime subcomponent for composite replacement. However, there is little literature on how conventional hardwood trailer decks react to in-service loadings. This problem was addressed through a comprehensive deck damage study, which was used to benchmark novel lightweight deck systems. Several lightweight replacement composite sandwich panels were designed, built and tested. Two different pultruded GFRP decks were also examined. While pultrusions do not offer the same level of weight savings as sandwich panels, the highly cost-driven nature of the trailer industry could dictate that their integration is the most reasonable first step to introducing composites into structural subcomponents. The final part of the thesis explores options for lightweighting the trailer chassis holistically. Trailer load cases were investigated through finite element modelling in Abaqus. A parametric model of a typical longitudinal trailer I-beam was developed using Python scripting and Abaqus. The model was expanded to analyse composite trailer structures. It showed that approximately 1,300 kg of weight could be saved by shape and material optimisation in a composite trailer. In summary, this research has shown that short-term trailer weight reductions can be effectively achieved through subcomponent replacement, while more significant reductions can be achieved in the long-term by a ‘clean slate’ composite redesign of the trailer chassis. The lightweighting strategies presented here are poised to have an increasingly important role in reducing the emissions of the road freight industry.

This thesis is an explorative, design-based research study towards the expressive potential of using actuators as design materials. Over three distinct phases of experimentation –all with their own particular aim– various sketches are developed that showcase different expressive qualities. These sketches consist of a variety of kitchen devices that are expanded with actuators. These actuators do not necessarily add to the functionality of the device, but rather to its expressiveness. The development of and reasoning for the sketches is clarified in an extensive way to clearly present all the insights that are gained throughout the design process. In the end, the sketches are discussed and reflected upon on the basis of the process-insights and relevant design theories.

Sustainable materials are prevalent within design, but industrial design lacks mass-manufactured product examples. This research explores this gap in knowledge to understand the influences affecting the selection of sustainable materials and how UK industrial designers could be better supported. A comprehensive literature review explores the selection of sustainable materials within the context of industrial design. Existing tools and resources designed to support industrial designers are analysed to understand the support provision and requirements. The research approach explores individual attitudes, and the influences towards and against selecting sustainable materials. Four UK companies were studied to understand how sustainable materials are considered and utilised for mass-manufactured products. Two frameworks were designed to support and facilitate sustainable material selection. The first depicts the overarching support requirements whilst the second presents the considerations and strategies. Both frameworks were evaluated by experts and previous participants. A workshop with designers evaluated the efficacy of the second framework when used as a tool The majority of industrial designers were aware of general issues of sustainability but rarely considered selecting sustainable materials. All four companies had experienced significant changes recently, including increasing resources and internal initiatives towards the use of sustainable materials. The market for sustainable materials is improving, but risks exist, such as fluctuating availability and market instability. A lack of awareness and understanding has meant that, in order to succeed, some companies have designed methods to educate stakeholders whilst designers have requested support to educate clients. Personal interest of the individual is a key driver, creating champions who raise awareness and boost confidence amongst colleagues. There is a need, not only for greater education and support, but also to improve engagement with sustainable material selection amongst industrial designers and others involved in the process.

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