MEL Composites, a supplier of technology and materials for the advanced composites industry, played a key role as a supplier of materials and consumables in the development of the innovative catamaran ZEN50, designed by Julien Mélot.

As the technical partner of the project, MEL Composites provided a complete package of materials, including carbon fiber fabrics, vinylester resin, structural cores, and auxiliary consumables, as well as comprehensive technical support throughout all phases of construction.

Technical support and process optimization
MEL Composites worked closely with the yacht's construction team, participating in the validation of materials through laminate testing, mold preparation, and the development of the resin infusion strategy. The technical team also supervised the infusion process to ensure laminate quality and process efficiency.

Additionally, the supply of custom machined cores allowed for optimization of structural weight, reduction of waste, and improvement of the geometric precision of the components.

Innovation in the construction of the ZEN50
The ZEN50, a zero-emission catamaran powered by solar and wind energy, combines high-performance carbon fiber with structural foam cores to achieve a lightweight, efficient, and high-performance structure.

One of the main innovations of the project was the integration of the outer skin, core, and inner skin into a single infusion process, while bulkheads and reinforcements were manufactured separately and integrated later, reducing weight and production waste.

Engineering applied on a large scale
Over a period of three months, the main sections of the hull were assembled in a mold, with the infusion of approximately 800 kg of high-performance vinylester resin in a controlled high-precision process.

The technical expertise of MEL Composites was crucial in the validation of materials, optimization of the laminate, and control of the positioning of each element, ensuring a final structure that is lightweight, strong, and optimized for maximum performance in navigation.

“The ZEN50 is a clear example of how structural design and advanced materials can be integrated to achieve exceptional performance. At MEL Composites, our mission has been to supply optimized materials for lamination and infusion processes, as well as to provide technical support to builders during critical manufacturing phases.”

“ZEN Yachts is at the forefront of zero-emission nautical technology, and we are proud to contribute to a project that marks the future of sustainable sailing. We are excited to see the first hull in the water soon.”

Eduardo Galofré
CEO, MEL Composites