Solutions for visualizing, understanding, and streamlining carbon emissions from various angles, such as business sites and products, corporate activities, and consumer behavior.
Efforts to conserve energy have been underway for several decades, but in recent years, the methods used have become more sophisticated, including AI and other technologies and billing methods based on usage. These solutions optimize energy usage.
Solutions related to batteries and hydrogen, such as electrification (EV) of mobility (means of transportation) such as cars and buses, which used to be fueled by gasoline, to reduce CO2 emissions, and to extract hydrogen for industrial use and to encourage its practical application.
Solutions related to batteries and hydrogen, such as electrification (EV) of mobility (means of transportation) such as cars and buses, which used to be fueled by gasoline, to reduce CO2 emissions, and to extract hydrogen for industrial use and to encourage its practical application.
Solutions that contribute to the fixation and absorption of CO2 in the atmosphere through forest protection and forest management, and offset the amount of greenhouse gas emissions that cannot be fully reduced through the purchase of carbon credits.
One solution is to reduce emissions in society as a whole by recycling metals, plastics, and other resources and products at various stages of economic activities.
Forward Engineering Japan, which leverages its expertise in manufacturing to provide support from advanced development to the mass production phase, is amazing.
Forward Engineering Japan supports the creation of products for future mobility by leveraging its deep knowledge of all aspects of ‘Monozukuri’, including the latest materials, components, structure, and design. We interviewed the company about its wide-ranging business domain and its thoughts on sustainable product development.
As countries strive toward carbon neutrality, the development of products that reduce CO2 emissions has become a prerequisite. To achieve this goal, even major manufacturers with abundant R&D budgets find it difficult to cover all the costs in-house. This is where a company that supports innovative manufacturing while predicting the future comes into play. We will introduce Forward Engineering Japan, a company that provides development support from concept study to mass production.
Spin-off from carbon fiber-based design and manufacturing
--Forward Engineering Japan is engaged in a wide range of businesses, including "development of new mobility vehicle bodies and structures," "development of battery packs," and "development of applications using new materials. How was the company born?
Nagashima There is a German company called Loading Automobile (now Loading Mobility), which originally designed and manufactured cars using carbon fiber (CFRP).
Hiroaki Nagashima
Managing Director, Forward Engineering Japan Co., Ltd.
After 14 years of experience in automotive OEM, he joined Mitsui & Co., Ltd in 2017. In 2018, he launched Forward Engineering Japan Co., Ltd., a Japanese branch of Forward Engineering GmbH, and as a representative, provides engineering and consulting services for automotive and mobility-related companies. services for automotive and mobility-related companies.
--do you mean that you started out designing and manufacturing sports cars?
Nagashima: Yes, and we are developing not only CFRP, but also more advanced materials and designs with an eye toward the future. CFRP is lightweight and has good performance, but it is expensive. While sports cars have focused on weight reduction, the future of automobiles is shifting its emphasis to how to reduce CO2 emissions. Supporting this shift is the main focus of our business.
--That's why the introduction to the business states "sustainable product development" at the beginning of the business introduction.
Nagashima: Reducing CO2 emissions is essential to the creation of new mobility. From this perspective, we have made "sustainable product development" one of our top priorities.
--I see. What kind of companies do you currently receive many requests from?
Nagashima: Automobile manufacturers and related parts and materials manufacturers account for 70-80% of the total, the remaining 10-20% are aerospace-related, and the remaining 10% are other industries. Our focus is on how to create added value with multi-materials, including steel and aluminum, as well as fiber-reinforced plastic materials.
The technologies we have developed in the automotive industry can be applied to other industries as well, so we believe we can be of help in a wide range of fields. We also hope to support future-oriented development by mutually applying the knowledge we have gained in each industry.
Supporting advanced development with global expertise
-Once again, what can you briefly say the company does?
Nagashima: We are a company that creates new solutions. There are various approaches to solutions, including materials and design. Currently, no company knows exactly what the right answer is, but we are developing a variety of solutions for the future.
We have offices in Germany, North America, Japan, and China, so we are utilizing our global knowledge and experience to support advanced development from the perspective of how we can provide added value for future mobility, while formulating various hypotheses of future visions.
--it seems that the strength lies in the development of car bodies and structures, which seems to be exactly what the automakers are good at.
Hirota: Automobile manufacturers have deep expertise in working with steel, leaving limited room for us to get involved in that area. However, when speed is critical and they begin exploring the use of fiber-reinforced composites or multi-material structures incorporating aluminum, it becomes increasingly difficult to handle development entirely on their own.
Our strength lies in structural design that fully leverages the potential of advanced materials. It’s in these situations that our expertise truly comes into play.
Yutaka Hirota
Design Engineer, Forward Engineering Japan Co., Ltd.
After 5 years of experience in body frame design and development at an automobile OEM, he joined FEJ in 2024, where he was involved in the development of EV bodies for CN, and keenly felt the difficulty of designing environmentally friendly vehicles with strict weight reduction requirements. Currently engaged in structural idea proposal and design development for realization of sustainable next-generation BEVs.
--Your clients include some of the world's most prestigious automakers. What was the catalyst for your leap forward?
Nagashima: First of all, the recent shift toward electrification has aligned well with our core strength. With the shift from gasoline vehicles to battery EVs, vehicle structures have undergone significant changes—and entirely new components, such as battery packs, have emerged.
In this evolving landscape, it’s no longer just about reducing weight. Optimizing thermal management, ensuring safety, and balancing cost have all become critical considerations. To achieve truly optimal design, materials must be used intelligently. This is exactly where our expertise in multi-material design and deep experience come into play.
--Why are you so good at solving difficult problems, such as future predictions that no one knows, not to mention your knowledge of new materials?
Nagashima: I believe the fact that our headquarters is in Germany plays a significant role. Germany tends to be proactive in adopting new ideas, and is remarkably quick to incorporate new materials and technologies from a mass production perspective. While Japan often takes a more cautious, deliberate approach, Europe tends to adopt promising innovations without hesitation. The insights and experience we've gained in that environment continue to benefit us today. More recently, we've established a presence in China. By working closely with our China office, we're able to integrate the latest technologies emerging from the fast-evolving Chinese market into our designs in a timely manner.
Having a global footprint also brings together team members from diverse cultural and professional backgrounds, enabling us to share knowledge and insights across regions. Thanks to this combination of factors, we're able to propose truly innovative and forward-looking solutions.
-Are there many competitors on a global scale?
Nagashima: Europe and North America have their fair share. We differentiate ourselves by predicting future scenarios based on technological development trends and needs in each market and proposing solutions based on these scenarios.
--Why did Mitsui & Co., Ltd invest in Forward Engineering?
Nagashima: Japan has an overwhelmingly strong background in the manufacture of carbon fiber. At the time, Forward Engineering was designing parts using carbon fiber for BMW, and it was anticipated that Japanese automakers would also use carbon fiber in the future.
In addition, each automaker must balance the difficult propositions of not only reducing the weight of the car body, but also making it highly recyclable and safe. In this respect, Forward Engineering had an advantage in its ability to skillfully arrange various materials. We thought it would be effective to collaborate with the company in terms of global response.
--Are you taking advantage of synergies with Mitsui & Co., Ltd.
Nagashima: Mitsui's global business bases and network are creating powerful synergies by spreading forward engineering technology throughout the world. In this era of great mobility change, the need for new materials and designs is expected to increase even more. We intend to further strengthen our collaboration and maximize synergies in the future.
Propose added value commensurate with the cost of CO2 emission reductions
--There often seems to be a trade-off between using the latest materials and technologies and achieving truly sustainable product development. Do you provide consulting services for material development as well?
Hirota: Yes. Currently, material manufacturers are also developing materials to lower CO2 emissions. In the case of automobiles, there are natural, bio-based materials and recycled materials. Naturally, there are issues such as cost, but there are active discussions on how to add value to these materials and how to use them.
-Is there now any business that does not have CO2 emission reductions in its agenda?
Hirota Yes, CO2 reduction is now a baseline requirement, and we are now in the world of how to add value while solving that problem.
Nagashima: Each country has set ambitious goals, such as achieving carbon neutrality by 2050. In the automotive industry, there’s a shared understanding that simply continuing along the current path won’t be enough to meet those targets. We need to develop new solutions, new materials with added value, and innovative design approaches.
--What exactly do you mean by value-added?
Nagashima: One example is parts or function integration. Let’s say there are two separate components, each with its own function. If we simply switch to a lower-CO₂ material, that often leads to higher part costs due to the material itself. But if we can redesign those two components into a single integrated part with multiple functions, and also reduce the manufacturing steps, we can potentially lower the overall cost. That’s the kind of added value we’re talking about.
Aiming at LCA reduction from a broad perspective
--In the introduction of your services, you mention "LCA and sustainable consulting". What kind of business is this?
Nakata: Many customers are calculating CO2 emissions in their own processes. However, it is difficult to calculate how much is emitted in other processes. Therefore, we make calculations and make proposals on how to reduce emissions over the entire lifecycle by taking a comprehensive approach.
Yusuke Nakata
Project Manager, Forward Engineering Japan Co., Ltd.
Graduated from the Department of Mechanical Engineering in March 2020. As a student, he was involved in student formula racing activities, including structural modification of the car body and introduction of CFRP wings. In April 2020, he joined Forward Engineering Japan Co., Ltd..He will propose structural ideas and design and develop sustainable next-generation BEVs.
--What do you mean by "top-down LCA" and "bottom-up LCA"?
Nakata: "Top-down LCA" is verification in the early stages of development. Detailed analysis takes time, so we start by considering countermeasures starting with the process that produces the largest amount of emissions. Bottom-up LCA" is a detailed examination at the same level as ISO certification at the stage where the concept and design have been determined to some extent.
--When considering LCA, it depends a lot on what you do at the end of the life cycle, such as recycling or disposal, doesn't it?
Nakata: That is a very difficult discussion. Recently, there are options such as reuse and repair, so we need to consider what kind of design allows for disassembly and separation.
--It seems to be a disadvantage for multi-materials, which is your company's forte.
Nakata: The ideal of "sustainable product development" is mono-materials, but there are many difficult components. Therefore, for example, it is necessary to design products that are easily disassembled so that they can be recycled after fulfilling their functions with multi-materials. To address such issues, we are also working with material manufacturers to develop technologies such as easily dismantlable adhesives.
Acting as a bridge between automobile manufacturers and material manufacturers.
--What kind of business is "battery pack development"?
Hirota: Knowledge of structure and materials is important in making battery packs. Material manufacturers are good at creating excellent materials, and automobile manufacturers are good at designing for mass production. On the other hand, for speedy development, it is necessary to bridge each other's technologies. In this context, we provide development support by, for example, conducting overhaul studies of mass-produced vehicles and tests using actual installed parts, and reflecting the results in the design.
--What kind of business is "application development using new materials"?
Hirota: Material manufacturers are developing new materials that comprehensively meet the required performance. However, simply presenting the characteristics of the material does not give either the automaker or the parts manufacturer an image of how to use it. What is needed is a solution proposal in the form of a business meeting in which the answer to the question of how the material can be used in which parts and to what degree it can add value to the vehicle is prepared.
However, since this requires knowledge of design, it is difficult for the material manufacturer to do this alone. With our involvement, we are able to make proposals that take into account not only usage, but also cost, weight, and CO2 emissions.
--you are really doing a wide range of things. What new services do you offer?
Nagashima: As I mentioned earlier, we have recently established a branch office in China. China is not only an important market in the automotive industry, but also a leader in terms of technology. We are looking to thoroughly investigate their technology and incorporate it into our customers' designs and development.
For example, we procure the latest battery packs from China to Japan for teardown and analysis to assess their design maturity. We also conduct tests such as artificially exploding batteries to measure the fire resistance performance of the surrounding components.
Revitalizing Japan's manufacturing industry with innovative ideas.
--Lastly, what is your dream that you would like to achieve through this business?
Nakata: When you hear the word "car," you probably imagine a car with tires and window glass. In the future, we would like to create something where the design and structure we have conceived will become the norm for mobility. We would like to create such excellent designs.
Hirota: Before joining Forward Engineering Japan, I was designing mass-produced vehicles for an automotive OEM. In the development of mass-produced vehicles, the balance between quality, cost, and weight is important, and as a result, new materials and ideas are not readily adopted and tend to be discarded. However, if this situation continues, we will not be able to compete with the rest of the world. In the future, we would like to propose innovative ideas and materials that could not be taken as options in the past and put them into practical use.
Nagashima: As Forward Engineering Japan, I would like to take on more and more challenges, not only in the field of automobiles, but also in aerospace and other fields. Personally, I'm driven by a desire to contribute to revitalizing Japan through meaningful work.
To that end, I want to enliven manufacturing in Japan while taking on new challenges so that people will enjoy working with us.
--Thank you very much for your time today.
Let's work together to create innovative solutions for the future! Please feel free to contact us first!
