Mat4Rail · Project

Fire-Safe Lightweight Composites and Modular Interiors for Next-Gen Trains

transportTestedTRL 5

Trains today are heavy and expensive to maintain partly because composite materials — the same lightweight stuff used in airplanes and racing cars — can't pass the railway industry's strict fire safety tests. Mat4Rail developed new fire-resistant resins and composites that finally meet those requirements, meaning train bodies can be built lighter without sacrificing passenger safety. On top of that, they redesigned train interiors with modular plug-and-play systems, smarter seats, and a more ergonomic driver's cabin — think of it like IKEA-style modularity for train interiors. The result: trains that weigh less, cost less to run, and are faster to reconfigure or repair.

By the numbers

consortium partners across the project

countries represented in consortium

SMEs involved in development

56%

industry ratio in consortium

demo deliverables (prototypes and mock-ups)

The business problem

What needed solving

Railway operators and manufacturers are stuck with heavy, corrosion-prone steel and aluminum carbodyshells because existing lightweight composites fail fire safety tests. This means higher energy costs, slower trains, and expensive maintenance. At the same time, train interiors are rigid and costly to reconfigure — every refurbishment is essentially a custom job.

The solution

What was built

The project delivered fire-retardant composite resins (epoxy, benzoxazine, hybrids) that meet railway fire safety standards, along with joining and repair technologies for these composites. On the design side, they built a physical prototype of innovative lightweight seats, virtual prototypes of a driver's stand and plug-and-play electrical system, and mock-ups reviewed by Shift2Rail members — 3 demo deliverables and 8 total deliverables.

Audience

Who needs this

Rolling stock OEMs (Alstom, Siemens Mobility, CAF, Stadler) looking for lighter train bodiesTrain interior and seating system suppliers seeking modular, fire-safe designsComposite material and resin manufacturers wanting to enter the railway marketRailway operators looking to reduce energy costs and speed up refurbishment cyclesShift2Rail / Europe's Rail Joint Undertaking members seeking next-gen vehicle technologies

Business applications

Who can put this to work

Rolling Stock Manufacturing

enterprise

Target: Train and rail vehicle manufacturers (OEMs)

If you are a rolling stock manufacturer struggling with heavy steel carbodyshells that drive up energy costs and limit train speed — this project developed fire-resistant composite materials that pass railway Fire, Smoke & Toxicity requirements. These composites are lighter and corrosion-resistant, which means lower energy consumption per trip and reduced long-term maintenance. The consortium of 16 partners across 7 countries validated these materials with virtual and physical prototypes tested with Shift2Rail members.

Rail Interior Systems & Seating

mid-size

Target: Suppliers of train seats, cabin interiors, and driver desk systems

If you are a train interior supplier dealing with long refurbishment cycles and costly one-off designs — this project built physical and virtual prototypes of innovative lightweight seats and a modular plug-and-play wiring system. The modular approach means interiors can be swapped or upgraded without gutting the entire car. Prototypes incorporated direct feedback from Shift2Rail Joint Undertaking members, ensuring alignment with operator needs.

Advanced Composites & Resins

SME

Target: Resin producers and composite material manufacturers

If you are a composites manufacturer looking to break into the railway market but blocked by fire safety regulations — this project synthesized fire-retardant epoxy and benzoxazine resins specifically engineered to meet railway Fire, Smoke & Toxicity standards. They also developed joining technologies (adhesive bonding combined with riveting and bolting) and repair methods for these new composites. With 8 SMEs and 9 industry partners in the consortium, the supply chain validation is already partially in place.

Frequently asked

Quick answers

What would it cost to adopt these composite materials compared to traditional steel or aluminum?

The project data does not include specific cost comparisons or pricing for the new composite materials. However, composites are noted for their lightness, repairability, and corrosion resistance — which typically reduce lifecycle costs through lower energy consumption and less maintenance. A cost assessment would require direct engagement with the consortium's resin producers and composite manufacturers.

Can these materials be manufactured at industrial scale?

The project produced virtual prototypes and physical prototypes (notably for innovative seats and plug-and-play mock-ups), but full industrial-scale production was not demonstrated within the project scope. The consortium includes 3 large industries and 7 SMEs with manufacturing capability, which provides a foundation for scale-up. Moving from prototype to series production would require additional certification and manufacturing line adaptation.

What is the IP situation — can we license these materials or designs?

The project was funded under a Research and Innovation Action (RIA) through the Shift2Rail Joint Undertaking. IP is typically shared among consortium partners under the grant agreement terms. Companies interested in licensing the fire-retardant resin formulations, joining technologies, or modular design concepts should contact the coordinator FUNDACION CIDETEC in Spain.

Do these composites actually meet railway fire safety regulations?

Meeting Fire, Smoke & Toxicity (FST) requirements for railway use was the core objective of the materials work stream. The project synthesized fire-retardant resins (epoxy, benzoxazine, and hybrids) and manufactured composite batches specifically to address this gap. Based on available project data, FST testing was conducted but full regulatory certification details would need to be confirmed with the consortium.

How long would it take to integrate these into an existing train design?

The project ran for 2 years (2017-2019) and produced virtual prototypes of the driver's stand and plug-and-play system, plus a physical prototype of innovative seats. Integration into an existing rolling stock platform would depend on the specific application — modular seats and plug-and-play electrical systems could be faster to adopt than full carbodyshell replacement. The project also developed repair methods and non-permanent joints, which supports retrofit scenarios.

Is the modular plug-and-play system compatible with existing rolling stock?

The plug-and-play system was designed to function as a modular technical and power backbone for electric utilities in train interiors. Virtual prototypes and mock-ups were built and reviewed by Shift2Rail JU members. Based on available project data, compatibility with specific existing rolling stock platforms would need to be assessed on a case-by-case basis with the engineering partners.

Consortium

Who built it

The Mat4Rail consortium is unusually industry-heavy for a research project: 9 out of 16 partners are industry players, with 8 SMEs and a 56% industry ratio across 7 countries (Austria, Belgium, Switzerland, Germany, Spain, Sweden, Turkey). This means the results were shaped by companies with real manufacturing and market needs, not just academic interest. The mix includes resin producers, composite manufacturers, and joining technology experts alongside 5 research organizations and 1 university, coordinated by FUNDACION CIDETEC in Spain. For a business looking to adopt these technologies, this consortium structure means multiple potential suppliers and technology partners are already familiar with the results.

FUNDACION CIDETECCoordinator · ES
COEXPAIR SAparticipant · BE
CENTRE SCIENTIFIQUE ET TECHNIQUE DE L INDUSTRIE TEXTILE BELGEparticipant · BE
ASAS ALUMINYUM SANAYI VE TICARET ANONIM SIRKETIparticipant · TR
HUNTSMAN ADVANCED MATERIALS (SWITZERLAND) GMBHparticipant · CH
AIMPLAS - ASOCIACION DE INVESTIGACION DE MATERIALES PLASTICOS Y CONEXASparticipant · ES
RISE RESEARCH INSTITUTES OF SWEDEN ABparticipant · SE
INSTITUTO TECNOLOGICO DE ARAGONparticipant · ES
UNIVERSITAET BREMENparticipant · DE
SPIRIT DESIGN - INNOVATION AND BRAND GMBHparticipant · AT
ACCELOPMENT SCHWEIZ AGparticipant · CH
IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK GMBHparticipant · DE

How to reach the team

FUNDACION CIDETEC is a research foundation based in Spain — they coordinated all 16 partners and can point you to the right technology partner for your specific need (materials, seats, modular systems, or joining technologies).

Order a report on this consortium See FUNDACION CIDETEC profile →

Next steps

Talk to the team behind this work.

SciTransfer can connect you directly with the Mat4Rail consortium partners best suited to your specific application — whether you need the fire-resistant resin formulations, the modular interior designs, or the joining technologies. Contact us to get a tailored introduction.

Order a report on this topic More in Transport & Mobility