CODEM’s Revolutionary Approach to Sustainable Manufacturing in the CALLUM SKYE Project

Introduction

CODEM is proud to be part of the ground-breaking CALLUM SKYE project, which premiered on the world-renowned Savile Row. This project exemplifies CODEM’s commitment to innovation, sustainability, and excellence in advanced composite solutions.

The Challenge

The project required a trusted partner to produce cost-effective, sustainable tooling for its body panels. The challenge was to ensure high-quality components for the initial low-volume production while minimising material usage, cost, and energy consumption.

The Solution

High-Performance Engineering

The CALLUM SKYE is engineered for an exhilarating driving experience both on- and off-road. It features:

• 42kWh Battery: Anticipated range of 170 miles with an ultra-fast charging option achieving a full charge in under ten minutes.
• Dimensions and Weight: Measuring 4,047mm in length, 1,900mm in width, and weighing just 1,150kg.
• Sportscar Performance: Accelerates from 0-60mph in under four seconds.

Sustainable Manufacturing

CODEM’s approach to sustainable manufacturing in the CALLUM SKYE project includes several innovative strategies:

1. Direct-to-Part Manufacturing: For the initial low-volume production, CODEM designed and manufactured direct tools for each body section, reducing material usage, cost, and energy consumption. This approach allows for easy re-machining of the tools if design changes are needed.

2. Sustainable Tooling Materials: All direct tools were made using Ru-bix Tooling Boards’ 100% bio-content HALO-S, providing an ideal balance of cost, performance, and sustainability.

3. Flax Fibre Bodywork: CODEM replaced traditional carbon fibres with flax fibre, grown and harvested in Scotland. This reduces transport, CO² emissions, and supports the UK economy. Flax plants absorb CO² during growth, storing it throughout their lifecycle. When composted or incinerated, the CO² is released back into the atmosphere, contributing to the natural CO² cycle.

4. Bio-Based Resins: Traditional epoxy resins were replaced with bio-based resins. The selected resin, SHD Composite Materials’ MTB350, contains 30% bio-content and has an excellent shelf life at room temperature, eliminating the need for cold storage and supporting CODEM’s sustainability goals.

Results

CODEM’s innovative approach in the SKYE project achieved substantial CO²e savings of over 20,000kg, setting a new standard for sustainable manufacturing. This success showcases CODEM’s ability to deliver high-quality, sustainable solutions that provide both environmental and economic benefits.

Why Choose CODEM?

• Innovation: Cutting-edge technology and manufacturing processes.
• Sustainability: Proven methods to reduce carbon footprint and environmental impact.
• Quality: High-performance materials and components.
• Collaboration: Close partnership with customers to meet design and performance goals.

Conclusion

The CALLUM SKYE project highlights CODEM’s commitment to sustainable manufacturing and innovation. By integrating advanced composite solutions and eco-friendly materials, CODEM not only meets high-performance standards but also significantly reduces environmental impact. This case study serves as a testament to CODEM’s leadership in delivering revolutionary, sustainable manufacturing solutions.