Shape Corp. roll forms martensitic steel bumper made with fossil-free steel

Shape Corp., a Grand Haven, Mich.-based global Tier 1 supplier, has manufactured a roll formed, production-intent martensitic steel bumper made with fossil-free steel from SSAB. This material is produced using HYBRIT technology, which replaces coal with hydrogen in the reduction process, powered by fossil-free electricity.

Shape reports it is the first automotive company to collaborate with SSAB in using this sustainable material in the development of this type of automotive component. SSAB aims to produce the steel at a commercial scale in 2026.

Shape has conducted rigorous testing, including bendability, fracture characterization, material toughness, delayed fracture testing, and welding evaluations that have shown the fossil-free steel does not compromise material properties or performance.

The roll forming process not only enables the usage of the highest-strength materials but also promotes efficient section design to optimize the usage of the material, all leading to sustainable manufacturing.

"Our material characterization activity ensures that the performance of this fossil-free steel matches that of the incumbent steelmaking process,” said Brian Oxley, project manager at Shape Corp. “Considering the full scope of emissions in the steelmaking and part production processes, we calculate a savings of over 10.74 kg CO2 (85.7%) for each bumper beam produced with this steel compared to a part made from conventional steel. Those savings can be closer to 20 kg per part when compared to a stamped bumper of similar performance. Those savings will continue to increase as emissions from both processes are reduced further."