Advanced lightweight materials for modern transport
Transport represents a third of Europe’s overall emissions. Decarbonising the sector is therefore critical to achieving the EU’s long-term goal(opens in new window) of net zero greenhouse gas emissions by 2050. While the electrification of vehicles is the main driver behind this, other factors are also important. Reducing vehicle weight for example can significantly decrease energy requirements, improve fuel economy and extend the range of electric vehicles.
Novel, multifunctional bio-composites
With this in mind, the EU-funded FOREST(opens in new window) project set out to develop novel, multifunctional bio-composites. The idea was that these novel bio-composites, combining a bio-based polymer matrix, or resin, with recycled carbon fibre, could be used to build lightweight vehicle parts. To achieve its aims, the project pulled together academic and industry partners with a wide range of specialist expertise. “These included major raw material and chemical producers,” says FOREST project member Fernando Ramos Saz from the AIMPLAS(opens in new window) Plastics Technology Centre in Spain. “The first stage was to develop different resins with high bio-based content.” An important constraint here was the development of these novel resins using raw materials and precursors originating from within the EU. Establishing European-based production in this way will help to address our over-reliance on imports, build a secure supply chain and reduce our overall carbon footprint.
Recycled carbon fibre for reinforcement
Three novel bio-based resins were developed within the scope of the project. The next stage was to use these products to build prototype parts essential to the transport sector. First though, each of the three resins had to be combined with recycled carbon fibre to provide reinforcement. “Our aim here was to use these composite materials to build three prototypes – a pilot cockpit dashboard, battery casings for electric vehicles and a bus roof,” explains Ramos Saz. Out-of-autoclave (OoA) manufacturing processes were used to build these prototypes. OoA technologies are innovative methods for producing high-performance fibre-reinforced plastic parts in a more cost-effective and energy-efficient manner than conventional autoclave processing. This may involve vacuum curing, compression moulding or pultrusion, instead of expensive, pressurised industrial tanks. In this way, the project sought to ensure that the manufacture of these parts would be economically viable. Once built, the prototype parts were rigorously tested for issues such as mechanical resistance and fire-retardant properties. “Fire protection performance is obviously very important,” adds Ramos Saz. “Bio-based fire-retardant additives were applied to ensure that the parts met the highest standards. This was challenging, because certification requirements are constantly evolving.”
Making bio-based precursors in Europe
These three pilots demonstrated that the production of the novel resins – and their application in lightweight bio-composite parts for transport – is feasible. “This work has opened up other areas of focus,” notes Ramos Saz. “These include establishing a viable production base and market for bio-based precursors here in Europe. This will be the focus of a forthcoming project proposal.” Any future project would focus on further developing the prototypes pioneered in FOREST, such as the battery casings. New partners will be brought on board. The project team is also interested in identifying potential new markets for these innovative lightweight biomaterials. Possibilities include the rail industry, as well as other potential applications in the field of aerospace. “Our aim is to continue to transfer our knowledge to the whole of the mobility sector,” says Ramos Saz.
