An EU-funded research project has developed advanced lightweight biocomposites for the automotive, aerospace, and bus sectors, claiming weight reductions of up to 35% compared with conventional components. The Forest project, coordinated by the Spanish Plastics Technology Centre (Aimplas), says the materials maintain performance, safety, durability, and electromagnetic interference shielding where required.
According to the project's findings, combining bio-based feedstocks, recycled carbon fibre, and functional additives makes it possible to produce transport components containing more than 50% sustainable materials without compromising performance, safety, or industrial feasibility. The initiative is part of broader efforts to improve transport efficiency and cut emissions by reducing vehicle mass.
Energy and cost savings in production
The project also reports that optimised processing of the biocomposites cuts energy consumption by 15% to 25% compared with conventional methods. Key improvements include accelerated curing chemistry that shortens production cycles by 20% to 40%, a one-shot moulding approach that eliminates intermediate processing steps, and the removal of the need for cold storage. Engineering costs are also reduced by 15% to 20%, thanks to simplified tooling, fewer mould iterations, and more robust processes.
Fernando Ramos, Forest project coordinator at Aimplas, said: “The Forest project proves that sustainability, lightweighting, and safety are not conflicting goals. By integrating bio-based chemistry, recycled carbon fibre, and multifunctional properties, we are reshaping advanced composites for future mobility.”
Implications for the automotive sector
While the project spans aerospace and bus applications, the automotive industry stands to benefit from lighter components that can improve the efficiency of battery-electric vehicles (BEVs) and plug-in hybrids (PHEVs). Reducing vehicle weight is a key lever for extending range and lowering energy consumption, a priority for automakers worldwide as they transition to electrified powertrains.
The development was reported by Chinese outlet First Electric (D1EV), which cited the original announcement from the project partners. The Forest project is funded by the European Union and involves collaboration across multiple European research and industrial organisations.
