Integrated Flywheel KERS – A low cost, lightweight hybrid solution

A Lotus Evora will soon carry a spinning flywheel in its gearbox, capturing energy normally lost during braking and reusing it for acceleration. This project tackles a stubborn problem in low-carbon transport: hybrid systems are effective but expensive and heavy. Current battery hybrids add cost, weight, and complexity that limit their adoption, especially in smaller or performance-oriented cars. Mechanical flywheels—already proven in Formula One—store energy as rotational motion rather than chemical charge, offering a lighter, cheaper alternative. The consortium aims to integrate Flybrid’s race-proven flywheel directly into a manual gearbox, adding an electronic clutch and control software to manage energy capture and release. If successful, the technology could cut CO₂ emissions from a production road car while boosting power and torque—without the weight penalty of a battery pack. The project uses matched funding from the Technology Strategy Board to push the system to production-ready status. Beyond the car itself, this UK-led innovation could generate future revenue and strengthen the domestic supply chain for low-carbon drivetrain components, making hybrid technology more accessible across vehicle classes.