Design problem averted for Levistor thanks to neutron diffraction measurements
04 Jun 2026 - Rosie de Laune
Levistor, a small company that delivers high-power, mechanical energy storage solutions for ultra-rapid electric vehicle charging, used neutron diffraction at the ISIS Neutron and Muon Source to measure residual stress as part of their design validation in readiness for production.
Challenge
Levistor has developed a low-cost kinetic energy storage system, which performs the function of a battery but has a cycle life two orders of magnitude higher than electrochemical batteries. Energy is put in by driving a motor on its rotor which is levitated by a magnetic field. When required, the motor becomes a generator releasing electricity. Levistor’s unique design reduces cost while guaranteeing safety, but they wanted to ensure residual stresses inside one component of the product were within allowable limits.
Solution
Thanks to the Industry Impact Fund (I2F), Levistor were able to access the Engin-X neutron diffractometer at ISIS to measure residual stress distributions within a specially manufactured prototype. I2F is a joint STFC-Innovate UK initiative designed to support UK businesses by providing funding for them to access STFC facilities and scientific expertise,
They were able to accurately measure residual stresses inside the component in critical areas of importance and account for this in combination with results generated by finite element analysis modelling. The magnitude and position of residual stresses were unknown prior to these measurements.
The I2F project has been extremely useful as a means of measuring residual stresses previously not known to Levistor. The support given by STFC staff was particularly welcome greatly increasing the efficiency of the process and avoided the application being a major distraction from the commercial activities of the company.
Keith Pullen, CTO Director of Levistor
Benefit
The project was highly successful given ISIS were able to quantify the level of residual of stresses in the design which were previously unknown. The presence of residual stress when added to stresses generated by high speed rotation greatly affects the resilience of the regions affected. The experiment was also successful in demonstrating that the required measurements were technically possible using neutron diffraction. Levistor would welcome the opportunity to return to ISIS, Engin-X to make measurements on future designs as a part of the validation process.
“The I2F project has been extremely useful as a means of measuring residual stresses previously not known to Levistor. The support given by STFC staff was particularly welcome greatly increasing the efficiency of the process and avoided the application being a major distraction from the commercial activities of the company.” Keith Pullen, CTO Director of Levistor and Hon Visiting Professor, City Saint Georges, University of London.
