AIMPLAS Develops Eco-Friendly Flame-Retardant Coatings and Composites

Amid growing concerns over the environmental impact of key industries like construction and mobility, there's a rising demand for materials that are lightweight, fire-resistant, and mechanically strong. To address this, AIMPLAS – the Plastics Technology Centre – is leading two IVACE+i and ERDF-backed projects focused on developing sustainable flame-retardant coatings and composite materials to improve safety in homes and transport.

The REFUGI project aims to develop phosphorus-based flame retardants through environmentally friendly mechanochemical processes. These retardants are being incorporated into varnish formulations tailored for wood applications, with the goal of enhancing the fire resistance of coatings used in the construction industry.

The use of flame-retardant varnishes has increased in recent years, as they offer a finish virtually identical to any wood coating, with the added benefit of greater fire resistance, delaying its spread and effects in the event of a fire. We are focusing on exploring different material sources to produce these flame retardants, prioritizing those that are renewable and recyclable.

Conducted in partnership with Omar Coatings and Decomader, this research seeks to boost the efficiency of flame-retardant production while minimizing the environmental impact of their manufacturing and application.

The NEOCOMP project focuses on developing high-performance, flame-retardant composite materials using advanced manufacturing technologies like Dry Fiber Placement (DFP) and additive manufacturing. These materials are designed to deliver superior mechanical strength, durability, and fire resistance, while also minimizing environmental impact in sectors such as construction, automotive, and aerospace.

The project will create flame-retardant thermoplastic binders for dry fiber, unidirectional tapes for DFP, and continuously reinforced 3D filaments. These innovations will enable the efficient production of complex preforms and custom composite parts with enhanced fatigue resistance and fire safety.

In collaboration with Ziur Composites and IT3D, the initiative aims to improve safety and sustainability in critical infrastructure. Both NEOCOMP and REFUGI are supported by IVACE+i under the 2024 non-economic R&D grant program, co-funded by the EU’s ERDF (2021–2027). Source: SpecialChem