en.Wedoany.com Reported - The SUPERPAN project is exploring new materials and manufacturing processes to develop a new generation of ultra-light, multi-directionally reinforced panels for vehicle structural components, aiming to promote recycling and reduce environmental impact in the transportation sector. The project is being carried out jointly by Birka Composites in Zaragoza, Spain, the plastics technology center Aimplas in Valencia, and the technology center Ideko in Elgoibar.

Vehicle weight is a decisive factor affecting energy consumption and emissions, yet the application of composites in vehicles still faces challenges such as complex processes, high costs, and reliance on manual operations. The SUPERPAN project is dedicated to developing more efficient, automated solutions that adapt to the emerging needs of the industry.

In terms of materials, the project first proposes the use of alternative materials based on thermoplastic matrices to establish recyclability. Manuel Gurrero, Operations Director at Birka Composites, stated that the design and selection of materials will be approached from a holistic perspective, considering the entire service life of the component while adapting to current mature manufacturing processes that use thermosetting resins.

The project also aims to reduce energy consumption during manufacturing to further strengthen its sustainability impact. Juan José Gordillo, a sustainable mobility researcher at Aimplas, noted that combining recyclable materials with more efficient processes is a key step toward a more sustainable transportation industry.

In terms of production processes, SUPERPAN integrates automated manufacturing technologies, including Birka's patented double pultrusion braiding (DPB) and ultraviolet (UV)-assisted prepreg curing. The production line also incorporates controllers for collecting process data to achieve higher quality control, fewer defects, and improved productivity and scalability.

Francisco Javier Vallejo from Ideko stated that collaboration between companies and technology centers is essential for developing solutions that can be successfully transferred to industrial environments. This collaboration enables the project to advance from a comprehensive perspective, combining scientific, technological, and industrial knowledge. SUPERPAN is part of the 2023 public-private partnership program, funded by the Spanish State Research Agency (AEI) and co-funded by the European Union.