Innovative research project combines biobased plastics and natural fibres for resource-saving vehicle components.

The Plastics Centre in Leipzig (KUZ – Leipzig, Germany) has launched the “BioSchaum-NFK” project together with partners from industry and research (BioSchaum = BioFoam, NFK – naturfaserverstärkte Kunststoffe = natural fibre reinforced plastics). The aim is to develop innovative lightweight structures based on biobased plastics and natural fibre-reinforced composites. These sustainable materials are intended to replace fossil-based materials and at the same time ensure mechanical stability, material efficiency, and recyclability.

Sustainable lightweight construction as the key to electromobility
Lightweight construction is a key factor for the efficiency and range of electric vehicles. However, current manufacturing processes are often cost-intensive and ecologically harmful. The “BioSchaum-NFK” project therefore relies on a combination of thermoplastic foam injection moulding and natural fibre reinforcements to reduce the amount of material used and improve the environmental footprint. This innovative approach is intended to significantly reduce both the weight of the vehicle components and the ecological footprint.

Technological innovation: foam injection moulding meets natural fibre reinforcement
The use of biobased plastics and natural fibre tapes in lightweight construction holds enormous potential, but poses technological challenges for the industry. The research team is therefore working on new material formulations and production technologies that combine environmental compatibility with high mechanical requirements. Thanks to the combination of foam injection moulding and natural fibre reinforcements, the material efficiency and mechanical properties of the components can be optimized. At the same time, the use of biobased materials enables a significant improvement in the carbon footprint and makes an important contribution to the circular economy.

Interdisciplinary cooperation in the ZIM network
As part of the Central Innovation Program for SMEs – ZIM (Zentralen Innovationsprogramms Mittelstand), leading partners from science and industry are working on the implementation of the project:

- Leipzig Plastics Center (KUZ): Development of new material formulations
- Merseburg University of Applied Sciences (Merseburg, Germany): research into innovative processes for the production of foamed bio-NFRP (natural fibre reinforced plastics) components
- YOUR Solution (Unterschleißheim, Germany): Development of efficient tool systems
- IDberlin Haller Roose (Berlin, Germany): Creation of sustainable design concepts
- Fuse (Zwenkau, Germany): Provision of high-quality natural fibre tapes
- E-cargo bike manufacturer (cooperation partner): Integration of components in real vehicle applications

This interdisciplinary collaboration covers the entire value chain – from material and process development, design and toolmaking through to industrial application. AT


Image: Schematic representation of the structure of a potential demonstrator component based on a “light electric vehicle”, source: IDberlin Haller Roose GbR

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