LIST and GRADEL conclude successful proof-of-concept collaboration

A fruitful collaboration between the Luxembourg Institute of Science and Technology (LIST) and engineering firm GRADEL has recently concluded. Launched in 2022, the joint project aimed to assess the viability of bio-based vitrimers to develop ultra-lightweight composite structures. Over the course of three years, LIST contributed scientific expertise on materials development, while GRADEL, through its robotic additive manufacturing commercialised with the name of GRAM, brought advanced engineering and manufacturing capabilities to engineer ultra-lightweight components.

The outcome: a successful proof-of-concept demonstrator designed to replace aluminium seat fixtures in an aircraft. This shows the technological potential of novel vitrimer-based composites to offer similar (thermo-mechanical) properties than the existing ultra-lightweight part, but with the strong asset of being fully recyclable.

“It wasn’t just about this one part,” explains Pierre Verge, project leader and new head of group in LIST’s Functional Polymeric and Particulate Materials (FPPM) unit. “We wanted to demonstrate that it’s possible to manufacture an application-relevant demonstrator for an aircraft seat fixture which features reduced weight and significantly enhanced sustainability by using FPPM’s novel vitrimer resin technologies.

While the project has officially wrapped up, the innovation it seeded is far from over. The proof-of-concept has laid the foundation for further work on similar components across aeronautics, automotive, and even space sectors in continuous collaborations for example with LIST’s Structural Composites (SC) unit and the Sustainable Composite Materials and Manufacturing Innovation Centre.

The inter-unit collaboration also shed light on next steps for industrial viability. “We’re now focused on refining aspects such as resin supply scalability,” Verge adds. “At this stage, LIST is still producing the resin in-house, but the aim is to transition towards a more industrial production model to further valorise the patented vitrimer.”

GRADEL and LIST are currently considering new project avenues that will build on this momentum.

Claude Maack, CEO of Gradel, said: "The composite manufacturing industry is awaiting recyclable resins capable of withstanding dynamic structural loads to replace non-recyclable epoxy resins. LIST’s vitrimer resin is an excellent candidate to be among the first on the market."