Low carbon footprint composite construction technology

Project title: Low carbon footprint composite construction technology

Agreement number: SKN/SP/631069/2025

Project implementation period: 14.04.2025 – 13.03.2026

Principal Investigator: dr hab. inż. Jacek Czarnigowski

Project value: 65 500,00 PLN

Funds granted for Lublin University of Technology: 65 500,00 PLN

Abstract: The aim of the project is to develop a low carbon footprint composite construction technology based on natural materials and its experimental verification on the example of a high performance racing vehicle. The project is being carried out by the Student Aerospace Propulsion Research Group, which has been carrying out the Hydrogreen project - building ultra-efficient vehicles competing in the Shell Eco Marathon international competition - for more than 10 years.

Currently, no team competing in the Shell Eco Marathon is built using composites based on natural materials. The technology developed will therefore be a significant innovation in the construction of high-performance vehicles, setting a new direction for the development of such vehicles in terms of lowering their carbon footprint.

The project comprises two parts:

1. Determination of strength parameters of composite materials based on natural materials;

The aim of this task is to determine the properties of composite materials, such as strength, degree of anisotropy, elasticity, hardness. In this case, the properties will be influenced both by the type of reinforcement phase material (origin of the fibres: flax, hemp, their garmature, type of weave), the arrangement of the layers of reinforcement phase material and the type of resin. As part of the work, samples of the different combinations of reinforcement phase material and resin will be made and subjected to laboratory tests to determine their properties. The work will be carried out in accordance with composite materials test methods, which will allow them to be compared with carbon composites. The result of this work will be a catalogue of composites based on natural materials. The expected variety of properties of the individual materials in terms of elasticity, directional strength, anisotropy and density will allow the recommendation of individual materials for selected areas of vehicle construction depending on local loading and food requirements. These requirements will be included in the summary of the developed catalogue, providing a basis for the selection of materials for structural design.

2. experimental verification of a composite structure based on natural materials;

The materials data obtained will form the basis for design work on the vehicle structure. The experience gained in previous competitions, combined with the optimisation of the structure on the basis of airflow simulations, will allow the development of an optimum vehicle shape in terms of use and minimum air resistance. The shape developed in this way will then form the basis of the design work for the composite structure of the monocoque. Finite element simulations of the composite structures, material data developed previously and guidelines for their selection in individual sections will be used for this. In addition, the technological limitations of manufacturing the structure under the conditions of the university. This will allow the development of a vehicle structure supplemented with requirements and technological recommendations for its manufacture. Design work will be carried out for both low carbon footprint materials and standard materials (carbon fibre-based with epoxy resins). This will make it possible to assess weight change of the structure with identical strength and stiffness.

The structure thus developed will then be manufactured. For this purpose, negative moulds will be developed and manufactured for lamination using the vacuum bag method, the necessary materials purchased and the individual components of the vehicle made. The result of this work will be a new vehicle design subsequently subjected to a series of strength tests.

The project is interdisciplinary involving two disciplines: mechanical engineering and materials engineering. The work related to the development of new composites and their properties and technical parameters is related to materials engineering, while the development of the technology for their use in the vehicle structure, the adaptation of the structure to the material possibilities, the development of design recommendations, the development and execution of the monocoque structure itself is in the discipline of mechanical engineering. The work in both disciplines comes together in this project with the common goal of developing and testing the technology under real vehicle conditions