REVOLUTIONIZING TRANSPORT WITH ELECTRIC AND HYBRID INNOVATION
Series Hybrid Electric HGV1 Truck
Explore how Astauto is pioneering the future of commercial vehicles with cutting-edge electrification technology, designed to reduce emissions and enhance efficiency.
Case study: Successful Implementation in Logistics
HYBRID Truck
Series Hybrid Electric HGV1 Truck
The Brief
In 2016/2017, under the Horizon 2020 program—EU’s research and innovation funding initiative spanning 2014–2020 with a budget of nearly €80 billion—Astauto assembled a consortium of seven companies (four from the UK, two from Italy, and one from Austria).
The goal was to design and develop an HGV1 truck and trailer featuring a Series Hybrid powertrain, low aerodynamic drag design, and low rolling resistance tyres to reduce fuel consumption and CO2 and NOx emissions. The project, titled ‘Aero Truck,’ had an allocated budget of approximately £14 million.
Deliverables
By the end of the project, Astauto and the consortium achieved the following deliverables:
- Submission of the Horizon 2020 application.
- Initial concept aerodynamic design.
- Initial concept aluminum chassis design.
- Preliminary powertrain specifications, based on WLTP drive cycle simulations at full GVW.
Our approach
Astauto’s approach for the ‘Aero Truck’ project involved the following steps:
- Formation of the Consortium:
- Astauto: Project coordinator, integrator, and vehicle designer.
- Equipmake Ltd: Hybrid electric powertrain provider.
- TotalSim Ltd: Aerodynamic designer and developer.
- Eddie Stobart Ltd: HGV operator and prototype tester.
- BSim SRL: Simulation software provider.
- YCom SRL: Composite manufacturer for the tractor cabin.
- Piotr Bilogan GmbH: Structural calculation specialist.
- Application to the Horizon 2020 Program: The consortium prepared and submitted the application to the EU offices in Brussels by February 1st, 2017.
- Proposal of Project Objectives:
- Develop a low-drag aerodynamic cab and trailer.
- Design the cabin with pedestrian and driver safety in mind.
- Incorporate a central driving position.
- Engineer the chassis and cabin using a combination of aluminum and composite materials for reduced weight.
- Integrate 4 to 6 in-board electric motors, depending on axle configuration.
- Include a gas turbine generator range extender.
- Utilize torque vectoring technology.
- Achieve 40% fuel consumption reduction, 40% CO2 emissions reduction, and 70% NOx emissions reduction.
- Employ HGV low rolling resistance tyres.
Post-Project Comment
Despite over a year of dedicated effort by all parties, the EU ultimately declined the funding request, deeming the project overly ambitious. However, as of 2025, long-haul HGV trucks from the USA and China are being produced following the same principles proposed in the ‘Aero Truck’ concept—a testament to its forward-thinking vision and relevance.
What Our Clients and Partners Say
“Since 2016, Sergio and his team have been invaluable partners in our expansion into the South American market for electric buses. Their deep expertise and strategic insights helped us navigate this evolving sector while also playing a crucial role in the design and development of electric buses tailored for both South America and the UK. Now, as we venture into agricultural machinery electrification for the global market, their continued support and innovative thinking remain instrumental in driving forward our vision.
Their dedication, technical knowledge, and ability to adapt to emerging opportunities make them an outstanding collaborator in shaping the future of sustainable transportation.”
Ian Foley
Chief Executive Officer
Equipmake Ltd
“From the very beginning of our journey developing the REE Corner and REE Platform, Sergio and Astauto have been invaluable partners to our R&D efforts. Their expertise in vehicle performance analysis, combined with advanced simulation tools, allowed us to make informed decisions on critical components—including motors, batteries, tyres, and aerodynamics. Thanks to their support, we rigorously evaluated our small to medium electric delivery trucks across a variety of drive cycles and typical mounting roads, ensuring optimal performance and efficiency. Their contributions have been instrumental in shaping our vehicles into cutting-edge solutions for the industry.
We couldn’t have asked for a more dedicated and insightful partner”
Ahishay Sardes
Director & Chief Technology Officer
REE Automotive Ltd.
“Over the years, AVL has been proud to collaborate with Astauto, a dedicated and innovative user of our simulation software. Their invaluable feedback and commitment have significantly contributed to the evolution and refinement of our tools, ensuring they meet the highest industry standards. Astauto’s proactive approach to leveraging our technology has not only enhanced their own projects but has also played a key role in advancing simulation capabilities for the broader Automotive and Motorsport engineering community. Together, we have fostered a relationship rooted in mutual growth, technical excellence, and shared vision for innovation.”
Mario Oswald
Team Leader
Engineering & Technology Powertrain Systems
AVL List GmbH
“Sergio’s contributions to Agrale have been instrumental in driving innovation and excellence. His expertise, dedication, and visionary approach have consistently elevated the team and its achievements.”
Edson A S Martins
Director
Agrale S.A.