MEL Composites collaborates with the bus and coach manufacturer Carrocerías Ayats in the development of composite material solutions applied to lightweight window frames, demonstrating the transfer of advanced technologies from the sports sector to the transportation industry.

The project introduces composite covers made with foam Rohacryl™, developed with technical support from MEL, which allow weight reductions of up to 80% compared to conventional solutions, contributing to improving passenger capacity and the operational efficiency of the vehicle, in line with the regulatory objectives of the European Union.

Ayats, an international benchmark in the manufacture of double-decker buses, integrates these solutions into its innovation strategy following the incorporation of Karbon Design, a company specialized in carbon fiber with which MEL has a long-standing technical collaboration.

The development has included the design of specific tooling, optimization of parts, and manufacturing through resin infusion processes and sandwich structures, with internally machined cores. The project evolves towards scalable production processes such as lightweight RTM and pressing.

MEL Composites has provided continuous technical support, contributing to the improvement of design, manufacturing efficiency, and automation of the production process, facilitating the industrial adoption of composite material solutions in the transportation sector.

“It has been a pleasure to collaborate with Carrocerías Ayats in the development of lightweight, reliable components ready for their future automated production. We are excited to continue this collaboration and further expand the integration of composite materials in their upcoming generations of vehicles.”

Eduardo Galofré

CEO, MEL Composites