Superpan is a research project focused on the development of lighter, stronger and more sustainable panels for the transport sector. The initiative brings together Birka Composites, the Plastics Technology Centre AIMPLAS and the technology centre IDEKO to create a new generation of ultralight panels with improved recycling potential for use in transport structures. The project addresses several of the sector’s current challenges, including vehicle weight reduction, improved energy efficiency, changes in composite-production processes and the transition towards more sustainable materials. Its objective is to reduce the weight of transport structures in order to improve efficiency, lower energy consumption and support a more sustainable model, while developing new materials and manufacturing processes that facilitate recycling and help reduce environmental impact.
The initiative is led by Birka Composites with the participation of AIMPLAS and IDEKO. It aims to develop multidirectionally reinforced panels for structural transport components, combining innovation in materials with advanced manufacturing processes to obtain more efficient and sustainable solutions.
Vehicle weight is a decisive factor in reducing energy consumption and emissions. Composite materials are therefore considered a strategic alternative because they offer high strength at lower weight than traditional materials such as metals. However, current manufacturing processes still face limitations, including complexity, high cost and dependence on manual operations. Superpan was created to address these issues through more efficient and automated solutions adapted to emerging sector needs.
"The aim is to advance towards more efficient materials that reduce the weight of structures without compromising safety or performance," says Manuel Guerrero of Birka.
More sustainable materials with greater recycling potential
One of the project’s main areas of progress is the use of materials that are easier to recycle at the end of their service life. Many components currently used in transport remain difficult to recover, creating an environmental challenge for the sector.
Superpan proposes an alternative based on thermoplastic matrices. These matrices improve the recyclability of composite materials and support the development of solutions aligned with circular-economy principles. Materials are designed and selected from a global perspective that considers the component’s entire service life and adapts established manufacturing processes that currently use thermosetting resins.
The project is also working to reduce energy consumption during manufacturing processes, reinforcing its sustainability objectives. Juan José Gordillo, a researcher in Sustainable Mobility at AIMPLAS, notes that "incorporating recyclable materials and more efficient processes is a key step towards a more sustainable transport industry."
Innovation in manufacturing processes
Superpan also introduces advances in production processes. The project integrates automated manufacturing technologies such as dual pullbraiding, DPB, a technology patented by Birka, and ultraviolet, UV-assisted curing of prepregs. These technologies are intended to improve process efficiency, reduce costs and decrease the variability associated with manual processes.
Controllers are also integrated into the manufacturing line to collect process data. This automation enables products to be manufactured with greater quality control and fewer defects, while increasing productivity and scalability.
Collaboration between companies and technology centres
The project is led by Birka Composites and includes the participation of AIMPLAS and IDEKO, two technology centres specialising in materials and advanced manufacturing.
AIMPLAS contributes its expertise in polymer materials, recyclability, characterisation and validation, as well as in the development of advanced manufacturing processes. IDEKO contributes its knowledge of automated manufacturing technologies and industrial digitalisation.
This collaboration makes it possible to address the project from a comprehensive perspective, combining scientific, technological and industrial knowledge to facilitate the transfer of results to the market. "Collaboration between companies and technology centres is essential for developing solutions that can be successfully transferred to the industrial environment," emphasises Francisco Javier Vallejo of IDEKO.
Superpan is part of the 2023 Public-Private Partnership programme, funded by the Spanish State Research Agency, AEI, and co-funded by the European Union. Through this initiative, the project contributes to the development of a more efficient and sustainable transport industry prepared to address future challenges.
