CIDETEC Concludes the European BIO-UPTAKE Project with the Development of Bio-Based and Recyclable Composites for the Construction Sector

An innovative prepreg material with 80% bio-based content has been successfully developed and can be stored at room temperature, overcoming the limitations of conventional materials.

The European BIO-UPTAKE project, launched in December 2022 with the aim of driving a green and digital transformation in the European manufacturing industry through the use of bioplastics, came to an end in May 2026. CIDETEC Surface Engineering played an active role in this international consortium, contributing its patented technology to develop sustainable, smart and high-performance solutions for the construction sector.

The main challenge of the BIO-UPTAKE project, coordinated by AITIIP, was to overcome the technical and environmental barriers associated with traditional composite materials — generally based on conventional fossil-derived polyester or epoxy resins and glass or carbon fibres of fossil origin — which slow down manufacturing processes and lack viable recycling options.

To address this challenge, CIDETEC’s Polymers and Composites unit combined natural flax fibre reinforcement with its exclusive 3R epoxy resin technology (Reprocessable, Repairable and Recyclable). In this case, the epoxy resin used as the basis for Part A of the formulation was also bio-based: DGEVA (Diglycidyl Ether of Vanillyl Alcohol) supplied by SPECIFIC POLYMERS. The result is a cutting-edge pre-impregnated material (prepreg) containing approximately 80% bio-based content by weight.

Room-Temperature Storage: A Logistics Breakthrough

One of the key competitive advantages of the material developed by CIDETEC Surface Engineering is that, unlike conventional prepregs that require strict and costly cold-chain storage conditions, this new bio-based composite can be safely stored at room temperature. This simplifies logistics, reduces energy costs associated with storage and optimises industrial manufacturing processes.

A Real Demonstrator for the Construction Sector

The feasibility and high performance of the material were successfully validated through one of the project’s flagship demonstrators: the manufacture of a ceiling panel for bathroom units.

For the development of this prototype, CIDETEC worked closely with consortium partner PODCOMP, whose technical expertise enabled the ceiling panel to be manufactured using the vacuum bag curing process. The demonstrator clearly showed that bio-based thermoset composites not only match the high mechanical and functional performance standards required by the construction industry, but also, thanks to CIDETEC’s 3R chemistry, fully retain their ability to be completely recycled at the end of their service life, effectively closing the loop of the circular economy.

BIO-UPTAKE had an overall budget of nearly €6 million, funded by the European Union under Grant Agreement No. 101057049. The consortium, led by the AITIIP Foundation, brought together 13 interdisciplinary partners from across Europe with the shared goal of increasing the use of bio-based composite materials in strategic sectors such as construction, healthcare and packaging, while reducing greenhouse gas (GHG) emissions by up to 33%.

With the completion of this project, CIDETEC Surface Engineering once again reinforces its leadership in the eco-design of sustainable materials and cutting-edge technologies for a cleaner, more efficient and circular manufacturing industry.