SciTransfer
FOREST · Project

Sustainable Lightweight Bio-Composites for Energy-Efficient Vehicles and Aircraft

transportTestedTRL 5

Imagine making car and plane parts that are as strong as carbon fiber but made from plants instead of oil. This project also finds a way to recycle old carbon fiber waste so it doesn't end up in a landfill. It's like giving high-tech materials a second life while making them greener and safer from fire.

By the numbers
100%
Carbon fiber waste recovery rate
40%
Bio-based content in PA6 batches by BASF
24%
Bio content in acrylic Elium resins by ARKEMA
100%
Bio-benzoxazines achieved by BITREZ
The business problem

What needed solving

The transport sector struggles to reduce vehicle weight and carbon footprints due to a dependency on fossil-based plastics and the difficulty of recycling carbon fiber waste.

The solution

What was built

Developed bio-based resins (polyamide, acrylic, benzoxazine) and bio-fire-retardant additives. Created a process to recover 100% of carbon fiber waste into semi-finished products.

Audience

Who needs this

Automotive OEM structural engineersAerospace composite manufacturersCarbon fiber recycling companiesGreen chemical resin producers
Business applications

Who can put this to work

Automotive
enterprise
Target: Electric Vehicle Manufacturer

If you are an EV manufacturer dealing with high battery weight and energy drain — this project developed bio-based resins and recycled carbon fiber components that reduce structural weight. This means less energy is needed to cover the same distance, extending vehicle range.

Aerospace
mid-size
Target: Aircraft Component Supplier

If you are a supplier dealing with strict fire safety and weight regulations — this project developed bio-based polymers and bio-fire-retardant additives. These materials maintain safety performance while lowering the carbon footprint of the aircraft structure.

Waste Management
SME
Target: Composite Recycling Plant

If you are a recycling plant dealing with large volumes of carbon fiber waste — this project developed methods to recover 100% of CF waste. This allows you to turn waste into high-quality semi-finished materials like non-wovens or organosheets for resale.

Frequently asked

Quick answers

What is the cost or price of these new materials?

Based on available project data, specific pricing or cost-per-unit for the bio-composites is not provided.

Has this been tested at an industrial scale?

The project involves testing at lab-scale and pilot plant level, with the goal of demonstrating technical feasibility at a demonstration scale.

How is the IP or licensing handled for the bio-resins?

Based on available project data, the specific licensing terms are not mentioned, though the consortium includes 11 industry partners who are developing the formulations.

What are the regulatory advantages regarding decarbonization?

The project focuses on reducing fossil source dependency and greenhouse gas emissions to align with European decarbonization goals for the transport sector.

When will these materials be available for commercial use?

The project period runs until 2026-05-31, suggesting that final demonstration and validation are ongoing.

Consortium

Who built it

The consortium is heavily industry-driven with a 73% industry ratio, comprising 11 industrial partners and 4 research centers across 8 countries. The presence of major chemical players like BASF, Arkema, and Clariant indicates a strong push toward commercial viability and industrial scaling rather than purely academic research.

How to reach the team

Contact AIMPLAS in Spain for technical specifications on bio-based PEC flame retardants.

Next steps

Talk to the team behind this work.

Contact us to connect with the FOREST consortium for licensing bio-resin formulations.

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