VIBES developed new bio-based bonding materials and successfully produced them on a larger scale. These materials were tested with different fibres and resins.
During RP1, VIBES made strong progress in developing sustainable composite materials. In WP1, researchers created innovative bonding materials (BBMs) using different chemical strategies, aiming to combine their strengths into one recyclable and durable solution. After thorough testing, the vitrimer-based approach was chosen for further development due to its excellent performance. WP1 was completed and shared results through scientific publications and events. Meanwhile, WP2 advanced in the creation of bio-based epoxy resins and carbon fibres made from lignin. These materials were combined to form fully bio-based composites compatible with the BBMs from WP1. , Early results were promising, and materials were shared with other teams for further testing.
RP2 confirmed the successful synthesis and upscaling of BBMs using supramolecular, vitrimer, and Diels-Alder approaches. These BBMs were tested for compatibility with various resins and fibres, and one BBM was scaled up to kilogram level, enabling its use in composite manufacturing.WP2 concentrated on the development of sustainable components for thermoset multilayer fibrous composites. A significant achievement was the scale-up of lignin/CAB precursor into carbon fibre weavings and unidirectional layers. The final carbonized patches were flexible and showed no signs of sintering, indicating successful processing and potential for industrial application.
In WP3, the consortium designed and developed inherently recyclable thermoset composites tailored for the construction, aeronautical, and naval sectors. Industrial partners validated the processability of VIBES-developed resins. The three different demonstrators were manufactured using flax and biobased carbon fibres, as well as baseline fibres. While VIBES resins met the technical requirements for civil infrastructure, flax composites showed lower mechanical performance, making them suitable for nonstructural applications. In the case of the aeronautic sector, mechanical testing revealed that tensile, flexural, Tg and many other properties are not only reached with VIBES systems but in some cases even overgrown. Naval sector composites using VIBES resins performed comparably to commercial alternatives. Proving to be a perfect solution for the industry.
Overall, the project demonstrated the feasibility of sustainable composite materials.The recycling aspect was addressed through the development of a solvolysis process using acetic acid and hydrogen peroxide. This method effectively separated the matrix from the fibres, with carbon and glass fibres remaining intact. A pilot recycling plant was designed and constructed, incorporating all phases from waste reception to fibre drying. The plant successfully scaled up the solvolysis process, demonstrating effective recycling of composite materials and high-quality fibre recovery. Life Cycle Assessment (LCA) and Social Life Cycle Assessment (s-LCA) showed that bio-based resins and fibres had improved environmental performance, especially when scaled up. Life Cycle Costing (LCC) revealed that bio-based carbon fibres were more cost-effective than benchmarks at pilot scale, while bio-based resins remained more expensive due to raw material costs.
The project aligned with EU Green Deal and Sustainable Development Goals, contributing to climate neutrality and circular economy objectives. Sector-specific Extended Producer Responsibility (EPR) models were developed, and stakeholder engagement was facilitated through workshops and roundtables. Exploitation strategies were defined for nine Key Exploitable Results, and business plans were created for the most promising innovations. The consortium engaged in extensive outreach through social media, newsletters, videos, and events. Workshops, roundtables, and a final conference were organized to showcase project achievements. Training activities included summer courses and industry-focused sessions, enhancing knowledge transfer and stakeholder involvement.
