This is an ongoing project at the Brookfield Sustainability Institute in partnership with AlumaPower. I am working on a diverse multidisciplinary team consisting of designers and engineers. My responsibilities in this team cover design strategy, research, and product design.
AlumaPower
Charging the Future. Changing The World.
Harnessing aluminum to unlock the future of clean, untethered energy.
The Technology
Unpacking The Aluminum Advantage
Aluminum has an incredibly high energy density at 2.5x that of gasoline or diesel. It is is abundant, non-volatile, lightweight, has an indefinite shelf life, and is easy to handle and transport.
The smelting of virgin or primary aluminum invests an incredibly high energy content in the metal. This is why aluminum has long been referred to as 'frozen electricity'. AlumaPower's proprietary technology is capable of extracting high energy densities from inexpensive impure aluminum, including 100% recycled or scrap aluminum.
Circular Economy & Fuel Stewardship
Our approach envisions a closed-loop fuel stewardship approach, using recycled aluminum and then recycling the off-product.
The Galvanic Generator Cell
As the AlumaPower Fuel Disc spins, it is slowly milled down and consumed (oxidized) in a water-based electrolyte reacting with an air-breathing cathode. This oxidization process generates electricity and heat with no local carbon emissions, and doesn't use rare earth minerals like in typical battery systems. As the system operates, an off-product, aluminum trihydrate, is collected for reuse or resale.
AlumaPower's Galvanic Generator design can be easily and intuitively refueled by exchanging a spent fuel disc with a fresh one, not unlike changing a CD or DVD.
How It Works
AlumaPower makes a Fuel Disc out of scrap or recycled aluminum.
Aluminum discs go into the galvanic cell to create energy.
A conjunction of cells, with supporting systems, makes a generator.
Discs are replaced periodically as they become depleted—think of it like a CD going into a CD player.
Service Vision
To support the scalability of galvanic cells across diverse power applications, we systematically evaluated a wide variety of component configurations, ranging from small units designed to compete with diesel generators or aide small solar panels, all the way to fully automated gigawatt facilities powering data centres, optimizing each for maximum power density and environmental compatibility.
Together with AlumaPower and third-party suppliers, we co-designed a service ecosystem anchored in the end-to-end customer journey and tailored to support AlumaPower's operational model.
Sub 10 kW Micro-Mobility Customer
At the smaller scale, manual disc reloading introduced
significant human factor considerations...
135 kW+ Data Centre Customer
...at the larger scale, the focus was on maximizing refuelling speed and power density through automated systems.
Case Study: Purolator Urban QuickStop (UQS)
We envisioned small-scale generators being the first to market, with AlumaPower providing the service and maintenance themselves. Larger operations would encompass custom solutions to handle fuel supply and off-product collection, as well as requiring advanced automated refuelling systems.
We worked with Purolator on a solution for their existing micro-mobility mini hubs and mobile pick-up lockers, with our generator working alongside solar panels or in remote areas.
AlumaPower deployed a 6-month in-field pilot of a pre-production system with Purolator. The integrated system provided grid independent power to charge their E-cargo bikes. The unit was sustained in the field with the support of AlumaPower.
Product Strategy
Product & Service Objectives
We identified design objectives that aim to improve performance by increasing energy density and refuelling speed while minimizing maintenance and ensuring safety. Design principles emphasize a user-centric approach, adaptability, and future-proofing by making sure we cover a wide-range of application scenarios. Business model options include various service models and customization to meet diverse customer needs.
Brand Vision
Our branding vision for AlumaPower focuses on creating a modern and intelligent clean-tech identity that reflects the utilitarian nature of its services. We opted for an understated look, incorporating a colour palette that mirrors the aluminum in the accent logo colour. This strategy is designed to be applied across various platforms, including a fleet of vehicles, software components, and the company website, ensuring a cohesive and frictionless service experience. The branding emphasizes a commitment to clean energy while presenting a professional and efficient image that resonates with both clients and stakeholders.
Proposed electric fleet van with modern and understated look, together with matching staff uniform and equipment.
Industrial Design
Visual Language Positioning
As this product is of a fairly utilitarian nature, we looked for inspiration in similarly utilitarian products: appliances, HVAC systems, generators, industrial equipment and consumer electronics. We also explored the idea of giving an architectural presence to this product, given its scale.
We gave a few our client different options and ultimately decided on a visual language that aligned with their brand—something simple, intelligent, clean & advanced.
Process
The process involved a lot of collaboration and feedback from the client. My goal was to create a design that was simple but still had some personality, so I integrated a bonnet that also functions as a vent cover. By using a different colour for the bonnet, I emphasized it as a key feature, adding visual interest and preventing the design from feeling monotonous.
A Modular System
To support the scalability of the generators across diverse power applications, we systematically evaluated a wide range of component configurations, optimizing each for maximum power density and environmental compatibility.
Style Alternatives
We presented various industrial design options for both product scales, considering their appearance when stacked side-by-side to highlight their modular potential.
Conclusion
As this project progresses and we at the Brookfield Sustainability Institute collaborate with AlumaPower on the second phase, I am eager to see this product come to fruition in the medium term. My experience working within this multi-disciplinary team and learning about new sustainable technologies has greatly expanded my understanding of the impact I can have as a designer on the future of sustainability. I am excited to witness the developments in aluminum-air battery technology and its potential to advance our climate objectives.