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

Purpose and goal

The Encore project aims to develop lightweight, high-performance hybrid composites by integrating natural fibers (NFs) and production waste from carbon fibers (CF) prepreg. A successful project will enable an increased use of NFs in structures and products with high eligibility requirements for mechanical properties and wear resistance as well as reduced use of expensive virgin fossil-based materials. This helps to increase the durability and circularity of composite materials.

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 energy-efficient 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.

Planned approach and implementation

The consortium in the Encore hypothesis represents a value chain from material supplier (SAAB Dynamics) to 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 DVF, and business development and identification of continuation potential.