Project description
Bio-based materials for lightweight and durable safety helmets
Fibre-reinforced composite helmets offer superior impact protection over thermoplastic alternatives. However, their manufacturing relies on a heavy, layered fabric design. This outdated stacking method leads to heavy gear, high production costs, material footprint and a risk of the layers separating under sudden stress. Supported by the Marie Skłodowska-Curie Actions programme, the INTRACHEL project will pioneer the design of lightweight, single-layer hybrid fabrics that weave natural and high-performance synthetic fibres together. Researchers will reinforce this optimised structure with bio-based nanofillers to improve fibre-matrix bonding and minimise delamination risks. INTRACHEL is expected to deliver eco-friendly protective shells that cut energy consumption and support global sustainability goals without compromising on critical life-saving performance.
Objective
Fiber-reinforced composite helmet shells offer enhanced resistance to dynamic impacts compared to thermoplastic alternatives. However, conventional manufacturing relies on stacking fabric layers, which leads to a heavier structure, higher costs, a persistent material footprint, and susceptibility to delamination. This research addresses the global demand for sustainable protective composites through INTRACHEL, which aims to develop intralayer hybrid woven composite shells for protective helmets by enhancing mechanical performance while reducing weight, cost, and environmental impact.
Aligned with the EU Green Deal, global sustainability goals, and Vision Zero, the project aims to replace energy-intensive synthetic materials with bio-based, sustainable, and protective composites. It focuses on combining natural and synthetic reinforcement to develop energy-efficient composites, while incorporating bio-based nanofillers to improve fiber-matrix bonding and minimize delamination risks.
The work plan involves the development of intralayer hybrid fabrics by combining natural and high-performance fibers within optimized weave architectures. Spanning 24 months, the project will encompass fabric development, structural optimization, interlaminar and dynamic impact strength assessment, multiscale modeling, and regulatory validation, culminating in lightweight helmet shells with performance and sustainability metrics. My doctoral research in structural composites and experience at Steelbird Helmets in protective technology affirms my capability to deliver this project. This fellowship will strengthen my expertise in sustainable protective composites under Prof. Mishra’s mentorship at CZU, leveraging their advanced facilities and industrial partnerships to build interdisciplinary skills, gain exposure to product development and certification workflows, and position me for future EU projects, industry R&D roles, and faculty positions.
Keywords
Project’s keywords as indicated by the project coordinator. Not to be confused with the EuroSciVoc taxonomy (Fields of science)
Project’s keywords as indicated by the project coordinator. Not to be confused with the EuroSciVoc taxonomy (Fields of science)
Programme(s)
Multi-annual funding programmes that define the EU’s priorities for research and innovation.
Multi-annual funding programmes that define the EU’s priorities for research and innovation.
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HORIZON.1.2 - Marie Skłodowska-Curie Actions (MSCA)
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Topic(s)
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Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.
Funding Scheme
Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
HORIZON-TMA-MSCA-PF-EF - HORIZON TMA MSCA Postdoctoral Fellowships - European Fellowships
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Call for proposal
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Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.
(opens in new window) HORIZON-MSCA-2025-PF
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Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.
165 00 Praha - Suchdol
Czechia
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.