Project Summary
Aeroflow is developing aerodynamic ‘shape-shifting’ HGV trailers to cut excess fuel burn. Traditional box-shaped trailers are built to maximise cargo capacity, but their aerodynamically inefficient shape becomes a drawback when the trailer is only partially loaded or completely empty. By adjusting dynamically to the unused space, these trailers reduce drag to improve fuel efficiency: delivering cost savings, increasing range, and lowering emissions.
Project Achievements
The TRIG project enabled Aeroflow to design, build and validate a full-scale minimum viable product of its shape-shifting aerodynamic HGV trailer concept. We successfully retrofitted a 40-ft container into a working prototype, integrating tapering sidewalls and structural reinforcements aligned with our patent-pending design. The project advanced our technology to TRL 6, demonstrating functionality in a relevant environment. We have planned shakedown and physical testing in the upcoming weeks. Critically, the project strengthened our IP position and commercial traction, initiating discussions with trailer manufacturers and fleet operators for pilot deployment and licensing. The grant further enabled the development of a clear technical roadmap toward on-road trials and production-ready designs.
Conclusions
The TRIG project has demonstrated that adaptive trailer geometry is both technically feasible and commercially compelling as a route to improving HGV efficiency. The transition from concept to full-scale prototype significantly de-risked the innovation, providing confidence in structural integrity, manufacturability and operational integration. Key learnings highlighted the importance of material selection, rigidity, and environmental resilience in dynamic panel systems. While further validation is required through on-road testing (TRL 7), the project confirms strong potential for real-world fuel and emissions savings. Engagement with industry stakeholders indicates clear market demand, particularly as operators seek cost-effective decarbonisation solutions. The next phase will focus on live trials, refinement of the actuation system, and formalising licensing partnerships to accelerate commercial adoption.
Next Steps
The immediate next step is to progress from TRL 6 to TRL 7 through controlled on-road testing with a haulage partner, generating real-world performance data on fuel savings, stability and durability. This will be supported by further refinement of the prototype, involving a derivation of the prototype built during the TRIG programme. Parallel to testing, we will continue engagement with the Vehicle Certification Agency to define the regulatory pathway and ensure compliance, leveraging existing exemptions for aerodynamic rear devices where applicable. On the commercial side, we will advance discussions with trailer manufacturers and fleet operators to establish pilot deployments and negotiate licensing agreements. Additional funding will be pursued to support this phase, including applications to the Freight Innovation Fund. Collectively, these steps will enable transition to a commercialised product, validating the technology in live logistics operations and positioning Aeroflow for early commercial rollout.
