Fibre Metal Laminate (FML) is a new type of material developed by the Delft University of Technology, the Dutch National Aerospace Laboratory and Stork Fokker AESP. Currently the FML type Glare® is applied in the Airbus A380. FML consists of thin layers of aluminium and glass fibre. These layers are embedded in a glue system. Because of the layered structure of the material it is possible to customize the plate material for specific applications. Advantages of FML over conventional materials are: low density, high pull strength and rigidity, low fatigue and high impact resistance.

There are opportunities for the new material beyond the aerospace industry. Research by Van der Meer & van Tilburg shows that it can be applied in road vehicles as well. The use of FML in the bodywork of trucks and trailers results in a significant reduction of the weight compared to currently used materials. The payload capacity of the trucks therefore increases and the energy use per transportation unit decreases. This results in advantages in terms of energy & fuel costs and environmental issues.

Ginaf Service enthusiastically performed an innovation project with regard to FML. The goal of the project was to give insight in the way FML could be applied on the bodywork of Ginaf trucks. Several tests were conducted which compared FML to traditional material. External advice was obtained to underpin decisions in design, material selection and joining techniques.

The construction was subjected to the ultimate test during the participation of the truck in the Dakar Rally in January 2007. Because of the extreme conditions this race was an optimal test environment. The results were amazing: FML showed itself to be superior to originally used materials. The main advantages were the the light weight construction, the high rigidity and strength, the impact and cracking resistance.

Results from the Dakar Rally proved that FML is nearly ready to be used in the 'normal' industry. The innovation project at Ginaf has contributed to a more wide-spread appliance of the material.

The extreme testing environment in the Dakar Rally provided lots of information about engineering, use and maintenance of the material. Also training material was developed in collaboration with the Aluminium Centre in Houten. This training material can be used in workshops for engineers, constructors, and producers. It is only a matter of time before new applications will be found for this material.