MEL COMPOSITES DRIVES THE ZEN50 YACHT WITH ADVANCED COMPOSITE MATERIALS

MEL Composites, a provider of technology and materials for the advanced composites industry, proudly announces its role as a supplier of materials and consumables for the revolutionary ZEN50 yacht, designed by Julien Mélot. As the exclusive supplier, MEL Composites provided all components, including carbon fabrics, vinylester resin, structural cores, and auxiliary elements, along with comprehensive technical support throughout the project.

MEL Composites worked closely with the yacht builders. This collaboration included the preparation of test laminates to ensure the expected mechanical properties, assistance in mold preparation, and the development of a precise resin infusion strategy. The company's experts also led the infusion process, ensuring superior quality and maximum efficiency.

In addition to supplying materials, MEL Composites provided precut cores that contributed to significant weight savings, reduced waste, and improved geometric accuracy. The ZEN50 catamaran, powered by zero-emission solar and wind energy, uses high-performance carbon fiber and structural foam core materials to achieve superior sailing performance while minimizing energy consumption.

A key innovation in the construction was the integration of the outer skin, core, and inner skin in a single resin infusion process, with bulkheads and reinforcements manufactured separately and attached afterward. This not only lightened the structure but also significantly reduced production waste.

Over a three-month period, the main hull sections of the ZEN50 were meticulously assembled in the mold, with approximately 800 kg of high-performance vinyl ester resin infused in a few hours to complete the structure. MEL Composites' technical expertise was crucial in testing all materials, validating the laminate, and ensuring that material positioning met strict requirements before the final infusion, guaranteeing a robust and lightweight vessel.

Eduardo Galofré, CEO of MEL Composites, highlighted the integral role of the company in this pioneering project.

The ZEN50 is an example of how design and materials can work together to deliver extraordinary performance. At MEL Composites, our mission was to provide materials optimized for lamination and infusion processes, and to support the builders—whom we recommended—during the crucial infusion stages.
ZEN Yachts is at the forefront of zero-emission nautical technology, and we are excited to see the first hull in the water soon.
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EDUARDO GALOFRÉ CEO, MEL COMPOSITES