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Research led by the Plastics Technology Centre (AIMPLAS) has completed testing of sustainable biocomposites developed under the European FOREST project. Consequently, the organization has demonstrated the technical feasibility of developing lightweight components for automotive, aviation and public transport with over 50% sustainable materials. Final prototypes achieved weight reduction of between 30% and 35% compared to traditional parts, meeting mechanical, safety and fire resistance requirements.
Industrial efficiency with sustainable biocomposites
Optimizations introduced reduced industrial energy consumption by between 15% and 25%. Likewise, formulation of fast-curing resins reduced cycle times by between 20% and 40%, eliminating the need for prior freezing during storage. Additionally, lower tooling complexity reduced engineering costs by between 15% and 20%.
To validate industrial performance, the initiative manufactured three representative demonstrators. First, a battery cover for electric vehicles was developed through compression molding using biobenzoxazine resin, recycled carbon and electromagnetic shielding. Second, a roof panel for aeronautical cabins was produced combining carbon sheets and biopolyamide overmolding. Third, continuous profiles for bus roofs were produced through thermoplastic pultrusion.
The project optimized three specific biological resins at pilot scale. On one hand, the bioacrylic system achieved 25% renewable content while maintaining recyclability. On the other hand, the biobenzoxazine matrix reached between 85% and 87% renewable carbon for technical molding. Finally, biopolyamide 6 development demonstrated 100% integration of recovered carbon fibers, ensuring circular economy without degrading structural properties of parts.
Source and photo: AIMPLAS
