EU Funds

General information about the project No. FENG.01.01-IP.01-A0SU/24-00


Project title: “Development and implementation of an innovative prepreg production technology”

Project Summary

New Era Materials sp. z o.o. has received funding from the European Union for the project entitled “Development and implementation of an innovative prepreg production technology”, under the European Funds for a Modern Economy Programme. The project involves activities carried out by New Era Materials sp. z o.o. aimed at developing and implementing an innovative technology for the production of prepregs. The project aligns with the company’s development strategy, which focuses on creating and introducing innovative solutions in the field of prepreg manufacturing.

Project objectives

The main goal of the project is to develop an innovative prepreg production technology. The scope includes the execution of R+D work (R+D module) and the implementation of its results in the company’s operations (Innovation Implementation module). The R+D module will include research aimed at developing the innovative prepreg production technology through the design, integration, and validation of individual components at the laboratory scale, then under conditions close to real-life, and finally at operational scale. It consists of three tasks:

1) Development and implementation of new technology elements

2) Defining interdependencies between the technological components and automation of selected process areas

3) Validation and optimization of the automated prepreg production process

    After the completion of the R+D module, the implementation module will begin, consisting of:

    1) Purchase of fixed assets required for the implementation of R+D results and the launch of project-related production, commissioning tests, and the start of industrial production.

      Planned outcomes

      The project will result in a process innovation that is at least nationally innovative and qualifies as an eco-innovation. Additionally, the implemented solution will enable the transformation of the current market by introducing automation, including automated changeovers. This will make it possible to flexibly produce small batches at competitive prices.

      Key measurable results of the project include:

      • Revenue from sales of new or improved products/services: PLN 151 500 000,00
      • Enterprises introducing product or process innovations: 1
      • Number of implemented R+D results: 1
      • Number of introduced process innovations: 1
      • Number of eco-friendly initiatives: 1
      • Private investment complementing public support (grants, financial instruments, etc.): PLN 32 955 411,82

      The innovation has social significance, particularly through its environmentally friendly production approach and reduction of health risks to workers – who, along with the company’s clients, represent the project’s target audience.

      Project value: PLN 58 146 473,47

      EU funding contribution: PLN 25 191 061,65

      General information about the project No. POIR.01.01.00-0786/19

      Project title: Development and optimization of resin system formulations to obtain prepregs with improved functional properties under sub-measure 1.1.1 of the Smart Growth Operational Programme 2014–2020, co-financed by the European Regional Development Fund. The project received the highest score and thus ranked first among the most innovative R&D projects in Poland in the plastics industry under the “Fast Track” competition.

      Project summary:
      Since 2013, New Era Materials has been contributing to the major development trends in prepreg manufacturing technologies. The goal of this newly developed project is to create globally innovative composite materials through pre-impregnated materials (branded as NEMpreg) made from modified epoxy resin systems.
      Composite materials play an increasingly important role and are currently used across most key sectors of the economy. Growing demand for lightweight structures in industries such as automotive, sports, construction, civil engineering, and energy opens new development opportunities.
      The use of pre-impregnated materials for producing composite components offers numerous advantages, including excellent reproducibility in the quality of the finished products. Ultimately, composites—such as those reinforced with carbon fibers—offer higher strength and lower weight than standard construction materials such as steel or aluminum.
      The fundamental assumption of the project, which directly translates into the novelty of its results, is the development of comprehensive solutions—ready-to-use pre-impregnated materials reinforced with various fibers that simultaneously demonstrate improved properties in all key areas (adhesion, shelf-life, curing conditions, infiltration), setting future directions for product development.

      Project objectives:
      To develop globally innovative composite materials in the form of prepregs (pre-impregnated materials) and manufacturing technology based on modified epoxy resin systems in three categories:

      1. Composite materials with carbon fiber reinforcements (CFRP),
      2. Composite materials with glass fiber reinforcements (GFRP),
      3. Other composite materials (aramid, basalt, natural, and hybrid fiber reinforcements).

      These materials will feature unique properties, including adhesion, infiltration level, fast curing time, product life stability, and stiffness.

      Planned outcomes:
      The main outcome—product innovation based on pre-impregnated materials—will be new to both the European and global markets. Its distinguishing features and functionalities significantly differ from current solutions. Key novel characteristics of NEMpregs include:

      1. Excellent adhesion: Achieved through various adhesion promoters and modifiers, eliminating the need for adhesives, reducing weight and cost, and improving environmental friendliness.
      2. Fast curing time: Enabled by a unique, single-component patented resin, allowing shorter press times and cost savings in production.
      3. Extended and stable shelf-life: Stable resin flow over time improves production efficiency and final product quality.
      4. Ease of use: NEMpregs are stiff and “dry,” making them user-friendly—an innovation on the market.
      5. Process automation capability: Optimized stiffness allows automated processing.
      6. Improved occupational safety: Produced using single-component resin, eliminating irritating substances and dust during cutting.
      7. Thick grammages: The dedicated production technology allows a range of thick reinforcements while maintaining desired properties and reducing processing time and cost.

      The materials will use “snap cure” type resin and be compatible with both low-cost (pressing) and standard (autoclave) manufacturing methods. Some variants will also be flame-retardant. The innovation focuses on improving material quality, usability, and technological value, reducing production costs.

      • Project value: PLN 27 034 353,74
      • EU funding contribution: PLN 12 207 932,37

      General information about the project No. POIR.01.01.02-00-0285/16

      Project title: Special bodywork with enhanced durability for a variant of a category “L” high-mobility vehicle “Triggo” intended for use in carsharing platforms and serial production technology of its elements based on innovative A.S.SET epoxy resins.

      Project Ssummary:
      Triggo S.A. owns the design rights for an innovative urban vehicle combining user safety with high mobility and spatial efficiency. Demand from carsharing platform operators justifies using technology enabling mass production. New Era Materials owns the chemical formulation rights for A.S.SET epoxy resins, suitable for composite parts production via extrusion.

      Project objectives:
      To conduct R&D work necessary to develop a special body for the Triggo microcar (category “L”), tailored for carsharing systems, along with the technology for its mass production.

      Planned outcomes:
      Triggo vehicles offer key advantages for carsharing platforms: reduced space for rental and charging stations, energy savings, and better cost-efficiency compared to category “M” cars.
      This electric urban vehicle combines the mobility and cost benefits of a two-wheeler with the safety and comfort of a car—thanks to its innovative variable-geometry chassis design, it occupies the same parking space as a motorcycle and requires only a motorcycle-width lane in traffic.
      These features significantly reduce commuting time lost in traffic or while parking, and ease congestion for other road users, including public transport.

      • Project value: PLN 12 865 664,04
      • EU funding contribution: PLN 8 150 315,98

      General information about the project No. POIR.01.01.02-00-0131/16

      Project title: “Demonstration of proprietary A.S.SET composite components manufacturing technology”. Under Measure 1.1 of the Smart Growth Operational Programme 2014–2020, co-financed by the European Regional Development Fund; Sub-measure 1.1.2 – R&D work for pilot/demonstration installations.

      Project summary:
      Before implementing the project “Demonstration of proprietary A.S.SET composite components manufacturing technology,” New Era Materials sp. z o.o. developed innovative solutions for composite manufacturers and customers, earning accolades such as the AVK award (association of the composites industry) for the most innovative process.
      Instead of traditional liquid (two-component) resins, this innovation uses a solid, single-component epoxy resin: A.S.SET POWDER. This simplifies and shortens the production process and reduces investment costs—significantly lowering the price of composite parts.

      Project objectives:
      To demonstrate, test, and verify the automated A.S.SET (Adjustable, Simple, ThermoSET) technology for manufacturing composite components for automotive, aerospace, and railway sectors.
      The company will build a demonstration plant with three main processes:

      • Production of A.S.SET POWDER solid epoxy resins
      • Production of A.S.SET SHEET thermoset organic sheets
      • Production of flat and 3D composite structures

      Planned outcomes:
      The project will result in a globally innovative process for manufacturing composite parts, including:

      • Automated, cost-effective production of A.S.SET POWDER resins
      • Automated production of A.S.SET SHEET thermoset sheets
      • Automated production of flat and 3D composite elements

      Product innovations include:

      • Modifiable A.S.SET POWDER
      • Modifiable A.S.SET SHEET and so-called semi-prepregs (using liquid resins)

      The outcome supports sustainable development policies. Composite parts made with A.S.SET SHEET significantly reduce the weight of end products, e.g., vehicles, leading to lower fuel consumption and CO₂ emissions. These materials are essential for electric vehicles.
      The automated A.S.SET technology will reduce energy consumption and VOC emissions, eliminating the need for cooling systems and high temperatures in sheet production.

      • Project value: PLN 32 904 415,36
      • EU funding contribution: PLN 13 161 766,14