Consortium develops lighter, more recyclable composite parts for vehic…
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Consortium develops lighter, more recyclable composite parts for vehicles
A Spanish consortium is developing new composite materials designed to make structural vehicle parts lighter and easier to recycle.
The SUPERPAN project, led by Birka Composites with Spanish research centres Aimplas and Ideko, is developing ultralight, multidirectionally reinforced panels for transport applications. The partners are combining recyclable thermoplastic materials with automated manufacturing processes to tackle two longstanding challenges for vehicle components: reducing weight while improving end-of-life recyclability.
Lowering the weight of cars can reduce the energy needed to move them, making lightweight composites an attractive alternative to steel and aluminium. However, conventional composites are difficult to recycle due to their structure and multi-material composition.
SUPERPAN is addressing these limitations by developing panels based on thermoplastic matrices, which offer greater recycling potential than composites made with thermosetting resins. The project is also adapting production processes to the new materials and seeking to reduce the energy consumed during manufacturing.
Birka, a Spain-based producer of fibre glass and carbon fibre composites, will offer its patented Dual Pull Braiding technology, which combines pultrusion with fibre braiding. Fibres are braided around unidirectional yarns embedded in a polymer matrix, providing reinforcement in several directions and improving mechanical performance.
The continuous process can produce lightweight, thin-walled profiles with complex geometries and high fibre content. Braiding angles can also be adjusted to meet different structural requirements, allowing components to be designed for specific loads and applications.
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