This work presents the methodology and results of the research into pre-treatments for thermal spray processes, applied to composites and technical polymers, as preparatory stage for the subsequent coating (ceramic and metallic) deposition via wire arc spray process. The research methodology includes the study of the thermal degradation of substrate materials, as well as the execution and characterization of mechanical (sand blasting), laser (surface texturing) and chemical (acid and base etching) pre-treatments. The quality of the proposed solutions is evaluated through visual inspection of the samples, optical micrography, surface roughness measurements, and mechanical adhesion testing of the coating. Finally, the selection of the most appropriate coating pre-treatment is made, considering technical and scalability criteria.

This work summarizes the methodology and results of the design of a light and safe vehicle structure based on high-strength steel, aiming at its introduction in urban environments. The structure is made of a tubular chassis design easily scalable and modular, taking into consideration safety features from the very beginning of the design stage. The structural integrity of the vehicle from a static point of view is validated through torsional and bending stiffness simulations and experiments, as well as fatigue assessment. The crashworthiness is evaluated by applying the procedures set in regulations R137, R95 and R94, with special emphasis on vehicle occupants’ protection and on other vulnerable road users, with the objective of achieving a 4-stars EuroNCAP rating.