SUPERPAN Develops Recyclable Composite Panels for Lightweight Transport

Updated on August 06, 2026 • 4 min read

The SUPERPAN research project is developing a new generation of recyclable composite panels designed to reduce vehicle weight while improving manufacturing efficiency and sustainability.

Led by Birka Composites (Spain) in collaboration with Aimplas and Ideko, the project combines recyclable thermoplastic materials with automated manufacturing technologies to produce lightweight structural components for future transport applications.

The initiative is supported through Spain’s 2023 Public-Private Partnership Programme, funded by the Spanish State Research Agency (AEI) and co-funded by the European Union.

Reducing Vehicle Weight Through Composite Innovation

Vehicle weight remains one of the most effective ways to improve energy efficiency and lower emissions.

While composite materials already offer significant weight savings, wider adoption has been limited by:

• High manufacturing costs
• Labor-intensive production
• Limited recyclability
• Dependence on thermoset resin systems

SUPERPAN aims to address these challenges by developing composite structures that are easier to manufacture, automate and recycle.

Moving from Thermosets to Thermoplastics

A major objective of the project is replacing conventional thermoset composite systems with thermoplastic matrices.

Unlike thermoset composites, thermoplastic composites can be reheated and reprocessed, making them more suitable for recycling at the end of a component’s service life.

According to Birka Composites, material selection is being approached from a full life-cycle perspective, considering not only structural performance but also manufacturing efficiency and end-of-life recovery.

Automated Manufacturing Technologies

SUPERPAN also focuses on increasing production efficiency through automation.

Key manufacturing technologies include:

• Dual PullBraiding (DPB), patented by Birka Composites
• Ultraviolet (UV)-assisted prepreg curing
• Integrated process monitoring
• Automated quality control

These technologies are intended to:

• Reduce manual operations
• Lower defect rates
• Improve production consistency
• Increase manufacturing scalability
• Reduce energy consumption

The integration of production data collection also supports more consistent manufacturing and process optimization.

Supporting Sustainable Vehicle Manufacturing

Beyond lightweighting, the project seeks to improve the environmental performance of composite manufacturing itself.

Researchers are working to:

• Reduce manufacturing energy consumption
• Increase material recyclability
• Improve production efficiency
• Lower overall environmental impact

According to Aimplas, combining recyclable materials with more efficient manufacturing processes represents an important step toward more sustainable transport systems.

Collaboration Across Industry and Research

The project combines expertise from three organizations:

• Birka Composites – composite material and manufacturing technologies
• Aimplas – sustainable materials and mobility research
• Ideko – manufacturing technology and industrial process development

According to the project partners, combining industrial and research expertise improves the likelihood of transferring new technologies into commercial manufacturing.

Professor’s Analysis

Many lightweight vehicle programs focus primarily on reducing component weight. SUPERPAN takes a broader systems approach by addressing three of the largest barriers to wider composite adoption simultaneously: recyclability, manufacturing automation and production cost.

The shift from thermoset to thermoplastic composites is particularly significant. While thermoset materials continue to dominate many structural applications, their limited recyclability is becoming an increasing concern as automotive and transport manufacturers pursue circular economy objectives.

Equally important is the project’s emphasis on automated manufacturing. Technologies such as Dual PullBraiding and UV-assisted prepreg curing target one of the industry’s long-standing challenges—reducing labor intensity while maintaining consistent quality. Automated process monitoring further supports higher production volumes, which are essential if composite structures are to compete economically with conventional metal components.

Rather than introducing a single new material, SUPERPAN illustrates how future lightweight transportation may depend on integrating recyclable material systems with scalable manufacturing technologies that improve both environmental performance and industrial productivity.

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