MEL COMPOSITES AND CARROCERÍAS AYATS COLLABORATE ON MANUFACTURING LIGHTWEIGHT COMPOSITE WINDOW FRAMES TO SUPPORT EU VEHICLE WEIGHT REDUCTION GOALS
MEL Composites se enorgullece de anunciar su colaboración con el fabricante español de autobuses y autocares Carrocerías Ayats, mostrando los beneficios de las tecnologías avanzadas de composites y los procesos de fabricación escalables desarrollados originalmente para el sector de artículos deportivos. El desarrollo conjunto de cubiertas ligeras de composite para marcos de ventanas demuestra cómo la innovación de procesos de MEL puede transferirse con éxito a la industria del transporte para cumplir nuevos objetivos normativos y de rendimiento.
As part of Ayats' commitment to reducing vehicle weight in line with evolving EU legislation, the new Rohacryl™ foam covers for window frames, developed with support from MEL Composites, are up to 80% lighter than traditional elastomer foam alternatives. This significant weight reduction directly contributes to increased passenger capacity and overall efficiency.
Carrocerías Ayats, based in Arbúcies (Girona), is a historic leader in the design and manufacture of double-decker buses and coaches, with a presence in over 20 countries. With an innovation record that includes being the first European manufacturer to obtain r.66 tilt test certification for double-decker vehicles, Ayats continues to push the boundaries of vehicle design and performance.
Although traditionally focused on steel and aluminum structures, Ayats saw a unique opportunity in its recent acquisition of Karbon Design, a Barcelona-based carbon paddle racket manufacturer. MEL Composites has supported Karbon Design for over a decade, developing efficient manufacturing techniques that have grown alongside the sport's popularity. This foundation proved highly valuable in adapting processes for automotive-scale applications.
El proyecto comenzó con el análisis de varios componentes de la cubierta del marco de la ventana seleccionados para el desarrollo de materiales compuestos. MEL diseñó herramientas a medida, incluidos moldes de aluminio y cartón para herramientas, y combinó de forma innovadora dos piezas distintas en un único molde para aumentar la eficacia de la fabricación. . Las piezas iniciales se produjeron mediante infusión de resina con laminado sólido y estructuras sándwich con núcleo de Rohacryl™ de 1 mm (los núcleos se cortaron internamente en MEL Composites). A medida que aumenten los volúmenes, se espera que la producción pase a métodos de moldeo RTM ligero y prensado.
This project is a testament to how composite material technologies proven in other sectors, such as sporting goods, can be adapted to address specific challenges in the automotive industry. It has been a pleasure to work with Carrocerías Ayats to develop lightweight, low-risk components suitable for future automated production. We are excited about the possibility of continued collaboration and expanding composite material integration into their next generation of vehicles.
Eduardo Galofre, CEO of MEL Composites
Eduardo Galofre, CEO of MEL Composites
