The move is part of plans to ultimately use the gravitational pull of a fully-laden iron ore train to charge its batteries in the downhill run to the port so there is enough power to return the unladen train to the mine. 

Fortescue’s tech arm, Fortescue Future Industries (FFI), said it will make its first EV truck module at its new UK facility in Banbury next month with completion in August.

The WAE (formerly Williams Advanced Engineering) facility is part of FFI’s global business “aimed at driving decarbonisation in all fields of economic activity, while building sovereign capabilities in emerging technology,” FFI said.

Andrew Forrest

The company bought WAE in March 2022 for $325 million and immediately proposed the manufacture of the zero emission ‘Infinity Train’, a regenerating battery-electric iron ore train project that uses gravitational energy to recharge its battery electric systems without any additional charging requirements for the return trip to reload. The project is expected to be completed by late next year

The latest decision for the WAE facility to produce batteries and power modules was accelerated by the recent signing of an Australia-UK Free Trade Agreement (FTA).

That triggered FFI to open a new state-of-the-art site in Banbury, Oxfordshire – which is additional to FFI’s other Oxfordshire facilities including the Kidlington factory which will open later this year – to manufacture advanced batteries and electric powertrains for sale to global parties.

Fortescue chairman Andrew Forrest said the expansion is part of Fortescue’s commitment to grow its British presence.

“With Fortescue’s investment, British engineering will be at the cutting edge of the green energy economy with WAE’s battery systems providing world leading technology to the entire global industrial sector,” Dr Forrest said.

“It is heartening to have the UK’s Trade Secretary at our factory in Oxfordshire to support this message of British technology excellence for both its people and its highly attractive working environment.”

FFI said that the Banbury location will produce a wide range of zero-emission products for the off-road sector including trucks and trains.

The factory will cover over 13,500 square metres and employ over 120 highly skilled engineers, technicians, apprentices and graduates, with recruitment for the industrialisation program now underway.

It will offer automated assembly for battery modules and packs, assembly of power conversion and power systems, as well as truck and train production support.

The first prototype build is targeted for July-August this year with the first mining haul truck module expected to be completed in August 2023.  

FFI said that the site will officially open in 2024 and will create job opportunities across all levels, including apprentices and graduates, acting as a showcase for a future rollout by WAE of further global high-tech manufacturing hubs.

The UK business and trade secretary, Ms Kemi Badenoch, said: “Fortescue’s investment in Oxford shows how this government is creating the right conditions to encourage cutting-edge advanced manufacturing companies to invest in the UK.

EVX

“This new state-of-the-art site will bolster the UK’s electric vehicle supply chain and create over 120 highly skilled jobs, helping to grow our economy.”

The opening of Banbury and its integration with other UK facilities follows Fortescue expanding to meet global demand for the development, manufacture, and supply of advanced electrification technology solutions to the off-highway sector.

It will offer automated assembly for battery modules and packs, assembly of power conversion and power systems, as well as truck and train production support.

The first prototype build is targeted for July/August 2023 with the first mining haul truck module due for completion in August 2023.  

WAE Technologies is a world-leading technology and engineering services business covering advanced battery and electrification technologies and product development.

It uses advanced simulation, testing, rapid prototyping and volume manufacturing. The company’s foundation was in 2010 when Williams Grand Prix Engineering Limited began diversifying its operations, creating a division which later became Williams Advanced Engineering. 

Following the acquisition by Fortescue in March 2022, WAE will continue to service its existing customers and commercialise new technology opportunities, in addition to playing a key role in supporting Fortescue’s global decarbonisation strategy.

By Neil Dowling