SUSPENS will develop a holistic approach, from bio-sourced and recycled materials to faster and lesser energy demanding processes, to produce sustainable composite structural parts, ensuring their manufacturability from the design conceptualization. This ambition is basically achieved by the R&D of the coupling bio/circular-materials and processes. SUSPENS will develop up to 95% bio-sourced thermoset resins, with formulations allowing fast cured manufacturing processes and properties adapted to high performance lightweight composite applications. To produce the parts, these resins will be combined with sustainable continuous reinforcing fibre such as natural based cellulose fibres, lignin-based CF, recycled CF staple yarn and continuous GF made from recycled GF for producing well engineered sandwich and hollow parts for transport industries. Some of these parts will be functionalised for added value and reduced assembling times. SUSPENS will also develop an innovative approach for sustainable, optimized energy reduced pyrolysis, using waste stream from the carbonization of precursors, reducing environmental impact of carbon fibre production. For the bio-epoxy, a specific solvolysis will be developed to separate the matrix from the fibres. SUSPENS will assess the valorisation of oil and organic components in these two recycling approaches to transform them into by-products. LCA and LCC studies will show that SUSPENS approaches, combining sustainable materials and processes, can reduce the CO2eq emissions at expected levels of about 40-50%. These achievements will be validated by producing three demonstrators with their respective business models: (1) automotive battery pack for electric vehicle, (2) sailing boat hull/deck and (3) aero-structure winglet part. SUSPENS results will pay-back in terms of lesser energy consumption and environmentally friendly products that can be recycled and expects to bring its assets to the market end of 2028.

Current technological demands are increasingly stretching the properties of advanced materials to expand their applications to more severe or extreme conditions, whilst simultaneously seeking cost-effective production processes and final products. The aim of this project is to demonstrate the influence of different surface enhancing and modification techniques on CF-based materials for high value and high performance applications. These materials are a route to further exploiting advanced materials, using enabling technologies for additional functionalities, without compromising structural integrity. Carbon fibre (CF) based materials have particular advantages due to their lightweight, good mechanical, electrical and thermal properties. Current generation CFs have extensively been used in a multitude of applications, taking advantage of their valuable properties to provide solutions in complex problems of materials science and technology, however the limits of the current capability has now being reached. MODCOMP aims to develop novel fibre-based materials for technical, high value, high performance products for non-clothing applications at realistic cost, with improved safety and functionality. Demonstrators will be designed to fulfil scalability towards industrial needs . End users from a wide range of industrial sectors (transport, construction, leisure and electronics) will adapt the knowledge gained from the project and test the innovative high added value demonstrators. An in-depth and broad analysis of material development, coupled with related modelling studies, recycling and safety will be conducted in parallel for two types of materials (concepts): • CF-based structures with increased functionality (enhanced mechanical, electrical, thermal properties). • CNF-based structures for flexible electronics applications. Dedicated multiscale modelling, standardisation and production of reference materials are also considered