Aimplas launches NEOCOMP and REFUGI projects

Source | Aimplas

There is growing concern about the environmental impact generated by key industrial sectors, especially in areas such as construction and mobility, where achieving materials with good mechanical performance, lighter weight and greater fire resistance plays a crucial role. In this context, Aimplas, the Plastics Technology Centre (Valencia, Spain) is working on two projects — REFUGI and NEOCOMP — funded by the Valencian Institute for Competitiveness and Innovation (IVACE+i), with support from the European Regional Development Fund (ERDF), to sustainably develop new flame-retardant coatings and composite materials that enhance safety in homes and transportation.

The NEOCOMP project, in collaboration with Ziur Composites and IT3D, focuses on developing high-performance, flame-retardant composite materials using advanced manufacturing technologies. This involves producing various parts through industrial processes such as dry fiber placement (DFP) and additive manufacturing. These composite materials must not only offer high performance in terms of mechanical strength, durability and flame resistance but also significantly contribute to reducing the environmental impact in construction and mobility.

Specifically, NEOCOMP will develop flame-retardant thermoplastic binders for dry fiber, unidirectional dry fiber tapes for DFP and continuously reinforced 3D filaments. According to Aimplas, these new manufacturing approaches will enable the efficient production of preforms with complex geometries and also the production of customized composite parts with improved mechanical properties, greater fatigue resistance and optimal fire resistance. This will open new opportunities in sectors such as construction, automotive and aerospace. 

The main objective of the REFUGI project is to develop phosphorus-based flame retardants using mechanochemical processes, representing a step toward more environmentally friendly methods. These flame retardants are being integrated into varnish formulations specifically designed for use on wood. This strategy aims to improve the fire-resistant properties of coatings used in the construction sector.

“The use of flame-retardant varnishes has increased in recent years, as they offer a finish virtually identical to any wood coating, with the added benefit of greater fire resistance, delaying its spread and effects in the event of a fire,” explain Carolina Acosta, lead researcher in mechanochemistry and reactive extrusion at Aimplas. “We are focusing on exploring different material sources to produce these flame retardants, prioritizing those that are renewable and recyclable.”

This research, carried out in collaboration with Omar Coatings and Decomader, aims not only to improve the efficiency of flame-retardant production, but also to reduce the environmental impact associated with their manufacture and application.

Both projects are part of the IVACE+i grant program for non-economic R&D projects carried out in collaboration with companies by technology centers in the Valencian Community for 2024, funded by the European Union’s ERDF under the 2021–2027 Operational Program.