The new materials are hybrids that combine thermoplastic polymer composites and metal to create lighter, high-quality parts that, until now, were limited to short production runs due to the time and costs required for their manufacture.
 
Composite materials offer numerous advantages derived from their high performance and low weight to sectors such as transportation. The problem is that their mass production is not yet a reality due to the complex production methods required.
 
To address the challenge of large-scale production, AIMPLAS, the Technological Institute of Plastics, is coordinating the RECOTRANS project. This European project aims to develop and demonstrate a new, more efficient and sustainable production method in the transportation sector, enabling high productivity in the manufacture of new multi-materials.
 
The result will be lighter, high-quality hybrid structures made of thermoplastic polymer composites and metal with lower production costs, which will also lead to energy and time savings, thus contributing to a reduction in carbon dioxide emissions.
 
Specifically, two innovative technologies will be developed: a microwave technology for pultrusion and RTM processes that will enable the production of long-fiber thermoplastic composites, and a laser joining technology that will allow for the addition of metal inserts to the composite parts. Using these new technologies, three demonstrators will be manufactured: a cab pillar for a Mercedes-Benz truck, a train roof panel manufactured by Stadler, and a vehicle door panel manufactured by Gestamp.
 
During the first phase of the project, progress will focus on defining the material and production system requirements for the three demonstrators, as well as on material selection and adaptation.
 
The 42-month project involves 13 partners from seven countries and has received funding from the European Union's Horizon 2020 research and innovation program under grant agreement number 768737. 

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