MEL Composites and Aresa Shipyards collaborate on four fishing vessels

The collaboration aimed to streamline manufacturing processes and reduce build times through an integrated approach. MEL was responsible for mould preparation, technical design, and engineering consulting for the vessel’s key structural elements, including the main deck, upper deck, and structural hull and deck bulkheads. According to initial estimates, this organization enabled Aresa to reduce overall production time by around 15%, while improving process consistency and repeatability.

“Our approach goes beyond simply supplying materials,” explains Eduardo Galofre, CEO at MEL Composites. “We leverage decades of composite expertise to provide complete solutions that address the technical and production challenges our clients face. With Aresa, we’ve created a workflow that allows their team to focus on hull construction, whilst we optimise and manage the build of the complex internal structures.”

Integrated Composite Structures

From a technical perspective, the project stands out for its advanced vacuum infusion technology, applied to glass fibre sandwich bulkheads. The structures are built using MEL Composites’ Aircell HR80 PVC core, precisely CNC-cut to ensure optimal accuracy and allow the integration of all longitudinal and transverse reinforcements within a single infusion process.

Another innovation is the use of a grooved foam core, which eliminates the need for mesh vacuum consumables during the infusion. This approach reduces both material waste and processing time while minimizing overall production waste.

The composite manufacturing was carried out in collaboration with the Catalan company Fibervent, which specializes in the repair and production of composite structures for the wind energy and marine industries. The components were produced off-site, with the transverse and longitudinal beams integrated directly into the infused part.

This off-site production strategy enabled just-in-time delivery to Aresa’s shipyard, optimizing scheduling and assembly efficiency.

Innovation Rooted in the Black Falcon V2.0

This new program follows the success of the Black Falcon V2.0 project, jointly developed by MEL Composites and Aresa Shipyards. The 15.2-meter high-speed interceptor, powered by four 450 hp Yamaha engines, can exceed 65 knots – a benchmark of performance and structural optimization.

For this earlier project, MEL provided a complete turnkey package, including kitted materials, consumables, infusion support, and on-site technical assistance.

Today, MEL Composites positions itself as a fully integrated composite solutions provider, covering the entire supply chain, from resins, reinforcements, foam cores, and consumables to tools and processing equipment.

With its in-house facility for core pre-processing and structural kit production, the company now offers ready-to-install composite components, helping shipbuilders achieve significant gains in production efficiency, material optimization, and quality consistency.