Lightweight high-performance and energy-efficient natural fibre/carbon fibre hybrid structures (Encore)

Purpose and goal:

The goal was to develop lightweight high-performance hybrid composites by integrating natural fibers (NFs) and production waste carbon fiber (CF) prepreg. The project has met the goal thanks to developing a novel process to use "multi-layer CF-prepegs" and later upgrading this process to add NF layers to it. A sandwich structure commonly used in the composites industry was manufactured and tested, with promising results, for example in terms of mechanical properties.

Expected results and effects:

Application area for Encore hybrid composites is primarily for sport. The know-how and experience obtained, such as concept design of hybrid composite materials, not only NF and CF, but prepreg and sheet molding compounds or NF/recycled GF or CF mats, for instance, as well as energyefficient manufacturing processes, such as compression molding, can be used for more lightweight, high performance and/or multi-functional composite structures and products in other areas, such as road vehicles and infrastructures.

Approach and implementation:

The consortium in the Encore hypothesis represents a value chain with product developer and manufacturer (Elpex Sweden AB and Podcomp AB), bridged by a composite research institute (RISE) as a key technology developer for sustainable composite solutions. Project is performed through selection and qualification of NFs and CF prepreg scraps, manufacturing of hybrid composites using selected NFs and CF prepreg scraps using double vacuum automation, and business development and identification of continuation potential.