At the closing stages of the project, r-LightBioCom has achieved a great milestone by developing and demonstrating novel fast-curing technologies that not only significantly reduce energy consumption and shorten production cycles, but also enable the integration of bio-based materials in advanced, high-performance composite manufacturing. This significant achievement in developing the innovative Ultra-Violet (UV) enhanced Resin Transfer Moulding (RTM) and Microwave-assisted vacuum infusion opens up new pathways to produce low-carbon composite materials for a range of demanding industrial applications.
Fast-curing bio-composites cut energy use and CO₂ emissions in advanced manufacturing
High-performance composites are essential for sectors like aerospace, automotive, and construction, but their production remains highly energy-intensive. Conventional autoclave curing can require several hours, consuming up to 15,000 MJ of energy per cycle and generating around 1,350 kg of CO₂ emissions. This creates a major barrier to more sustainable composite manufacturing.
To address this, r-LightBioCom has developed two complementary fast-curing technologies throughout the project, which are aimed at reducing energy demand, shortening processing times, and improving compatibility with bio-based resin systems.
The two innovative curing technologies
Ultra-violet (UV) enhanced Resin Transfer Moulding (RTM)
A newly developed RTM mould integrates UV-based photopolymerisation to enable rapid curing of bio-based epoxy resins.
“Rapid curing technologies, especially UV cationic induced photopolymerization could make a revolution on the manufacturing composite sectors, giving rise to affordable composites maintaining the mechanical properties for more sustainable and stronger structures.”
Microwave-assisted vacuum infusion
r-LightBioCom also demonstrated a microwave-based curing process that significantly accelerates production. The example trials showed that curing times were 15–20 minutes, and energy input was measured at approximately 1 MJ for representative sample production. This approach enables rapid consolidation of composite laminates while lowering thermal exposure and processing time. The rapid-curing technologies are also scalable from the laboratory with relative ease. In r-LightBioCom, TRL5 was achieved for this process (previously TRL3), overcoming limitations such as uneven curing degree due to thickness by means of simulation and real-time control of resin curing kinetic. However, in the case of the microwave-assisted vacuum infusion technology, the major issue for scalability is the size of the equipment required for the process. On the other hand, the large equipment is not required for UV-curing with photopolymerization.
Enabling bio-based composite solutions
A key innovation of r-LightBioCom is the integration of fast-curing technologies with bio-based resins and sustainable fibres, enabling lower-carbon composite materials for demanding applications. The two curing processes developed in r-LightBioCom were validated using r-LightBioCom-developed bio-based resins, with various sustainable fibres such as glass, basalt, and flax.
The results show significant energy savings: UV + RTM curing reduces energy use by 57% (from 12.8 to 5.4 MJ/kg), while microwave-assisted vacuum infusion achieves a 56% reduction (from 41 to 18 MJ/kg), highlighting the strong potential for more energy-efficient composite manufacturing. In terms of Climate change, the RTM+UV estimate 21% below RTM methods and the Vacuum infusion + UV estimate 6% below Vacuum infusion alone.
Industrial relevance and market potential
The technologies developed within r-LightBioCom target high-value European industries, including automotive, aerospace, maritime, electronics, construction, and more. By reducing curing time and energy demand, the solutions offer potential for increased production throughout, lower operational energy costs, and reduced environmental footprint of composite manufacturing. Depending on the industrial sector, the technologies could reach the market as early as 2 years. In other sectors were rigorous homologation processes are required, such as those in the aeronautical sector, the technologies could reach the market in 5-10 years.
European collaboration driving sustainable innovation
These results within r-LightBioCom were achieved through close collaboration between European research and industrial partners. CIDAUT developed a specialised RTM mould for frontal photopolymerisation and a microwave-assisted vacuum infusion system. AEP Polymers formulated customised bio-based epoxy resins, while AITEX selected and supplied optimised fibre materials. Together, these innovations enabled the successful production of high-quality bio-based composite materials suitable for high-performance industrial requirements.
By combining bio-based materials with energy-efficient processing, r-LightBioCom contributes to Europe’s sustainability and industrial goals to reduce industrial greenhouse gas emissions, increase resource efficiency in manufacturing, and finally, to strengthen the competitiveness of European advanced materials industries. The demonstrated reduction of up to 72 % in energy consumption and CO₂ emissions from the innovating curing processes highlights the potential of fast-curing technologies to support Europe’s transition towards climate-neutral manufacturing, exploiting advanced composite manufacturing methods.
