ICE von Siemens

High rigidity & low product weight

Warschauer U-Bahn von Skoda

Durability & corrosion resistance

U-Bahn Berlin - Fußbodenheizung und Fußboden mit hoher Schalldämmung

Adapted to technical requirements

Metawell Boden und Treppe im RS Zero von Stadler

High static & dynamic strength

Metawell® aluminium lightweight panels and components in rail vehicle construction – Lightweight, stable, versatile

Metawell® lightweight components made from aluminium sandwich panels are highly regarded in rail vehicle construction due to their versatility. Since the early 1990s, they have been used worldwide in high-speed trains, carriages, metros and trams.

They combine low weight with high bending strength and dimensional stability, meet the highest fire safety requirements and can be used for sound insulation. With their high-grade, coatable and printable surfaces, Metawell® aluminium sandwich elements can be adapted to the required design. The easily formable Metawell® Aluflex allows the realisation of complex sandwich constructions. Furthermore complete systems can be delivered, e.g. with attachments, handles, holders, integrated heating cables…

Builders and designers happily rely on Metawell® lightweight components in railway vehicle construction – for good reason: with the lightweight aluminium sandwich panels, solutions that meet challenging technical and economic requirements can be realized for different applications.

Metawell® & Metawell® Aluflex

Various applications of Metawell® in rail vehicle construction

Lightweight, stable and functional – perfect for modern sustainable rail vehicle construction
Typical application areas include exterior applications, ceiling elements, floors, built-in elements, air ducts and components for access aids and maintenance covers. 

Metawell® at a glance

  • Reduce weight, increase efficiency: Less weight means better performance.
  • Durability: Due to excellent corrosion protection properties.
  • Quick and easy installation: Prefabricated components.
  • Engineering expertise: Development of technical solutions in collaboration with the customer.
  • Functionality: Corrugation channels can be used for sound insulation and cable installation.
  • Safety: Certified materials guarantee fire safety and safety standards.
Skoda tram prague

Exterior applications

Metawell® is suitable for outdoor use – especially for exterior cladding and casing systems.

  • Low weight: Low weight per unit area – every gram counts.
  • Appearance: Extremely smooth surfaces possible
  • Corrosion protection: Cover sheets and core material of Metawell® are corrosion-protected, ideal for outdoor weather conditions

Flat and curved ceiling elements

Metawell® is ideal for use in ceiling constructions – wherever lightness, stability and design freedom are required.

  • Low weight: High rigidity with minimal intrinsic weight allows use with few fixing points. Elements can be installed quickly and efficiently.
  • Functional integration: Parts of the ceiling can also be used as cable ducts or for technical installations.
  • Design flexibility: Flat or curved ceiling elements – optionally with powder-coated surfaces.
Metawell Decken im ICE Zug von Siemens
Metawell Boden mit Heiz- und Akustikfunktion für Stadler EC 250

Floors (acoustically effective and heated if necessary)

Metawell® floor panels have been specially developed to meet the high demands of rail vehicle construction. They combine maximum load-bearing capacity with low weight, enabling efficient and durable vehicle designs.

  • High load-bearing capacity: Withstands large surface and point loads – mounting points for handrails or similar components can be integrated
  • Durability: Due to high corrosion protection
  • High bending stiffness: Enables larger spans with reduced weight
  • Functional integration: Corrugation channels can be used for additional functions such as the integration of heating cables or improved acoustics to increase passenger comfort

Built-in elements

Metawell® is suitable for functional and durable equipment elements in rail vehicle construction. Thanks to their low weight and high stability, they are suitable for a variety of applications.

  • High stability: Resists mechanical stress and offers increased protection against vandalism
  • Possible applications: Ideally suited for tables, switch cabinets, seat boxes, stairs and other interior elements
  • Design freedom: flat and curved elements
Metawell Schaltschränke für Stuttgarter Straßenbahnen AG von Stadler
Metawell Klimakanäle für Züge

Air ducts

Metawell® can be used to produce air ducts – i.e. air distribution systems that ensure even distribution of supply and exhaust air in rail vehicles.

  • Low weight: Enables manufacturing large-area air duct components with minimal weight.
  • High rigidity: The stable sandwich structure eliminates the need for additional stiffeners. In addition, a reduced number of fastening points can be used. This allows for economical and quick installation.
  • Efficient air flow: The structure and precise manufacturing ensure optimum flow characteristics and quiet operation

Partition walls

Thanks to its lightweight construction, Metawell® is ideal for partition walls and compartment doors in rail vehicle construction – especially where strict weight requirements and high safety standards must be met.

  • Certified fire safety: EN 45545 HL3
  • Functionality: Cables can be integrated into the corrugation channel
  • Surface quality: Powder-coated on request – for a more uniform surface with increased scratch resistance and cleaning agent resistance
Metawell Trennwände in Zügen
Metawell Wartungsdeckel in Zügen

Components for access aids and maintenance flaps

Entrance areas of rail vehicles must withstand exceptional stresses – extremely high load cycles, weather-related influences and contact with aggressive substances such as road salt are commonplace here.

  • High load-bearing capacity: Corrosion-protected lightweight aluminium panels withstand extreme surface and point loads
  • Durable and robust: Proven in ramps, sliding steps, maintenance flaps, cover plates and lift systems
  • Weather-resistant: Withstands moisture, road salt and other environmental influences

Product features

Outstanding product features of Metawell® in rail vehicle construction
Lightweight. Stable. Durable.

Metawell® lightweight aluminium panels set new standards in innovative rail vehicle construction. Their exceptional combination of low weight, high rigidity and complete recyclability makes them the ideal solution for rail vehicle construction.

Component and system delivery – Due to the high degree of vertical integration, components and systems can be delivered adapted to technical requirements.

Durability due to corrosion resistance – 5000 alloy series with a minimum magnesium content of 2.7% and the use of an additional primer on all surfaces, including the core material, guarantee exceptionally high corrosion resistance.

Engineering expertise – Our dedicated engineering team provides support in design and implementation, even for complex applications.

Clever lightweight design – Thanks to its innovative corrugated core, Metawell® achieves high bending stiffness with minimal weight. In addition, further functions (e.g. heating cables, cables or sound insulation) can be integrated into the corrugation channels.

Engineering expertise
From the panel to the finished component

Metawell® not only offers high-quality lightweight aluminium panels, but also comprehensive engineering expertise for rail vehicle construction. Our experience ranges from the initial concept idea to series production – we support our customers in the planning, design and implementation of tailor-made solutions.

Tailor-made solutions: Together with leading rail vehicle manufacturers, we develop components that are precisely tailored to vehicle architecture, static requirements and functional needs.

Prototyping and testing: We support the development of prototypes, carry out mechanical tests and thus ensure reliable functionality in series production.

Ready for series production: Our solutions are designed for series production – from the first sample to fully tested series parts. This also includes the creation of technical drawings, production approvals and assembly concepts.

Practical optimisation: Through our close cooperation with vehicle manufacturers, we can optimise processes, reduce weight, shorten assembly times and increase material efficiency.

Easy processing and installation of Metawell®

Easy to work with using standard tools – also suitable for local content projects

Metawell® not only offers outstanding material properties, but also scores highly with its particularly easy and flexible processing. By using standard tools, projects can also be implemented where a high level of local content is to be achieved.

Processing tips & downloads

We provide the following technical information to ensure safe and efficient processing:

Processing tips
Shaping Metawell® Aluflex

Maximum design freedom with Metawell®
Versatility in surface design

Metawell® is not only lightweight and rigid – it is also versatile in terms of surface design.

Wet painting
For custom coloring, even in small quantities. Adhesive-coated panels can be painted directly without extensive pre-treatment (max. 100°C!).

Powder coating
Available on request – offers high durability and an elegant surface finish.

Digital printing
Ideal for large-scale, brilliant designs. The high flatness and low thickness tolerance enable razor-sharp print images on specially coated panels.

Foil lamination
Self-adhesive decorative foils or transfer adhesive foil enable quick and easy design.

Approvals for Metawell® in rail vehicle construction
Approved. Tested. Safe.

  • Certified according to ISO/TS 22163:2017 (IRIS)
  • Gluing certification according to EN 17460 Class A1
  • Welding certification according to EN 15085-2 Level CL1
  • Fire protection HL3 according to EN 45545

Metawell® products are corrosion-resistant, low-maintenance and durable
Long-lasting protection and maximum safety

Metawell® products are made from particularly corrosion-resistant aluminium alloys and, thanks to their complete primer protection, are ideal for use in rail industry.

Corrosion protection at all levels: Every aluminium layer – even the corrugated core material – is coated on both sides with a specially developed corrosion protection primer. This protective coating clearly distinguishes Metawell® from other products, in which the core material often remains untreated.

Strong hold thanks to perfect adhesive bonding: The primer not only protects against corrosion, but also forms the essential basis for a durable and stable adhesive bond – a decisive prerequisite for the longevity of our products.

High-quality alloy for demanding applications: Both the cover sheets and the core material are made of aluminium from the 5000 alloy series with a magnesium content of over 2.7%. These alloys are considered particularly corrosion-resistant and are therefore ideal for use in the rail sector.

Sustainability in operation

Metawell® lightweight design for rail vehicle construction

The use of Metawell® aluminium lightweight panels in rail vehicle construction is much more than a technical improvement – it is an active contribution to sustainable mobility.

The significant reduction in weight significantly lowers energy consumption and emissions over the entire service life of a vehicle. At the same time, maintenance costs are reduced – which is both ecologically and economically convincing.

Durable and efficient – for decades

Metawell® products are designed for a long service life that can span the entire life cycle of the vehicle. This is made possible by the use of corrosion-resistant 5000 series aluminium alloys with a minimum magnesium content of 2.7% and comprehensive protection provided by a primer on all surfaces, including the interior of the product. The result: less material replacement, lower maintenance costs and a longer service life.

Sustainability that pays off

The equation is simple: less weight = lower energy consumption when moving = reduced operating costs and emissions.

This potential for savings has also been scientifically proven – for example, by a study conducted by the Institute for Energy and Environmental Research in Heidelberg (ifeu), which analysed the energy savings over the entire life cycle of a train.

Metawell® as a recyclable lightweight construction material

Metawell® aluminium lightweight panels offer a future-oriented solution for modern rail vehicle construction – sustainable, resource-efficient and economically convincing. Thanks to material, design and the use of recycled aluminium, they are a good example of sustainable lightweight design.

100% recyclable – no need to separate materials: Metawell® panels can be completely and easily recycled at the end of their life cycle – without having to separate the materials first.

Made from approx. 80% recycled aluminium: Our products consist of around 80% secondary aluminium – this saves natural resources and reduces the carbon footprint.

Less material. More efficiency: Thanks to the sophisticated design of Metawell®, less aluminium is used.

Raw material bank for your rail vehicle: Aluminium retains its value. At the end of its service life, Metawell® can be sold as a high-quality secondary raw material.

Downloads

References

Metawell Referenzen im Schienenfahrzeuge

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