smartMELAMINE · Project

Fire-Resistant Lightweight Fabric That Cuts Insulation Costs Across Industries

manufacturingPilotedTRL 8

Imagine a fabric that's lighter than what you use today, blocks heat and sound better, and won't catch fire — all at a lower price. That's what this team figured out how to make from melamine, the same tough material used in kitchen countertops. They invented a way to spin it into ultra-fine fibers using industrial meltblown machines, producing rolls wide enough for real factory use. They've already tested it with over 100 potential customers in automotive, protective clothing, and industrial filtration.

By the numbers

100+

potential customers consulted during development

300mm

pilot-scale production width achieved before project

2,400mm

industrial-scale production width target achieved

TRL6-7

technology readiness at project start

SME partners in consortium

countries involved (DE, SI)

The business problem

What needed solving

Technical textile buyers in automotive, protective clothing, and filtration face a growing gap between what regulations demand (fire resistance, thermal performance) and what current materials deliver at an acceptable cost and weight. Existing insulation fabrics force trade-offs: you get fire resistance but add bulk and expense, or you keep it light but fail safety tests. Companies need a single material that checks all boxes — fire-resistant, thermally insulating, acoustically dampening, lightweight — without premium pricing.

The solution

What was built

The project built an industrial-scale meltblown production process for melamine fiber fabric, scaling from 300mm pilot width to 2,400mm industrial width. The key deliverable is "Industrial scale demonstration samples" — actual full-width fabric rolls ready for customer testing and integration.

Audience

Who needs this

Automotive Tier 1/2 suppliers producing thermal and acoustic insulationProtective clothing manufacturers (firefighter gear, industrial workwear)Hot gas filtration companies (power plants, cement, waste incineration)Aircraft interior insulation suppliersNonwoven converters looking for differentiated technical textile products

Business applications

Who can put this to work

Automotive insulation

mid-size

Target: Tier 1 or Tier 2 automotive suppliers producing thermal and acoustic insulation components

If you are an automotive insulation supplier struggling with rising fire safety regulations while keeping weight and cost down — this project developed a melamine-based meltblown fabric that delivers fire resistance, thermal insulation, and acoustic dampening in one lightweight material. The team validated it with more than 100 potential customers and scaled production to industrial width of 2,400mm. It replaces multi-layer insulation stacks with a single material at costs below current solutions.

Protective workwear

SME

Target: Manufacturers of thermal protective clothing for firefighters, industrial workers, or military

If you are a protective clothing manufacturer facing demands for lighter, more comfortable gear that still meets strict flame resistance standards — this project created an ultra-fine melamine fiber fabric proven at pilot scale (300mm) and scaled to industrial width (2,400mm). The material offers fire resistance without the bulk and weight of traditional solutions, directly addressing wearer comfort and safety compliance.

Industrial filtration

mid-size

Target: Companies producing hot gas filtration systems for power plants, cement, or waste incineration

If you are a filtration company dealing with high-temperature exhaust gases and need filter media that survive extreme heat while maintaining efficiency — this project built a meltblown melamine fabric with inherent flame resistance and fine fiber structure. Industrial scale demonstration samples have been produced, and the material's thermal stability makes it a direct fit for hot gas filtration applications.

Frequently asked

Quick answers

How does the price compare to existing insulation materials?

The project objective explicitly states the melamine meltblown fabric can be produced at costs well below competitive solutions. This is achieved through the dedicated meltblown process that enables efficient large-scale manufacturing. Exact pricing is not disclosed in the available data.

Can this be produced at industrial scale?

Yes. The project started with pilot-scale production at 300mm width and successfully scaled up to industrial width of 2,400mm. A deliverable titled 'Industrial scale demonstration samples' confirms that full-scale production was achieved and demonstrated.

What is the intellectual property situation?

The consortium reports unlimited licenses and patents that guarantee freedom to operate. A joint venture called SML was established to facilitate commercialization. This suggests the IP is secured and commercially structured for market entry.

What safety and regulatory certifications does this material have?

The fabric offers inherent fire resistance from the melamine base material. Based on available project data, specific certification details are not listed, but the material was tested in industrial environments at TRL6-7 and validated with more than 100 potential customers who confirmed it meets their requirements.

How quickly could we integrate this into our production line?

The material is produced via meltblown technology, which is standard in the nonwovens industry. The consortium of 3 SME partners from Germany and Slovenia combines melamine processing and meltblown expertise. Based on available project data, industrial-scale rolls at 2,400mm width are designed for direct integration into existing converting and lamination processes.

What markets has this been validated in?

The team spoke with more than 100 potential customers across automotive insulation, thermal protective clothing, and hot gas filtration. Interest was confirmed across all three segments. The EuroSciVoc classifications also reference aircraft and transport applications.

What is the current project status and next steps?

The project closed in April 2019 after completing its SME Phase 2 objectives. The joint venture SML was set up for commercialization. The project website smartmelamine.com may have current product availability and contact information.

Consortium

Who built it

This is a lean, commercially focused consortium of 3 SME partners from Germany and Slovenia — with zero universities or research institutes involved. That's a strong signal: every partner is industry, every partner is an SME, and the team was built purely for production scale-up and market entry. The coordinator, Melamin Kemicna Tovarna from Slovenia, is a chemical manufacturer with direct melamine expertise. The German partners bring meltblown technology know-how. Together they formed a joint venture (SML) specifically to commercialize the product, which shows real commitment beyond the project timeline.

How to reach the team

The coordinator is Melamin Kemicna Tovarna d.d. Kocevje in Slovenia. SciTransfer can facilitate a direct introduction to the commercialization team.

Order a report on this consortium

Next steps

Talk to the team behind this work.

Want to test smartMELAMINE fabric samples for your application? SciTransfer can connect you directly with the SML joint venture team and arrange sample delivery. Contact us for a no-obligation introduction.

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