Biocomposites: From Egyptians to Aerospace

Biocomposites are not a new concept. Natural fibres were used in construction materials thousands of years ago, including by the ancient Egyptians. Today, the same principle is accelerating into advanced sectors such as automotive, aerospace and renewable energy.

Specialists in advanced composite prepreg materials, SHD Composites are collaborating with CHCx3 partners to explore the performance of UK grown hemp and flax fibres within high performance resin systems. These fibres are being integrated into existing matrix materials to form composite panels designed for demanding applications.

Having previously relied on imported hemp materials, SHD Composites sees UK sourced fibres as an opportunity to strengthen local supply chains and reduce the environmental impacts associated with long distance transport. Regional sourcing enhances sustainability credentials without compromising on quality or performance.

What Are Biocomposites?

Composites are engineered materials made from two primary components. The first is a binder, known as the matrix, which holds the structure together and distributes loads. The second is a reinforcing fibre, which provides strength and stiffness. Reinforcing fibres may be woven or non woven.

When one or both of these components are derived from biological sources, the material is known as a biocomposite. Traditionally, both matrix and fibre have been made from synthetic, non renewable materials such as petroleum based resins and glass or carbon fibres.

Most biocomposites currently in use combine natural reinforcing fibres with partially synthetic resins. These materials are often referred to as natural fibre reinforced plastics. Common natural fibres include flax, hemp, jute, kenaf and wood fibre.

Significant progress has been made in developing bio based reinforcing fibres. However, the matrix component remains more technically challenging. Plant oils derived from hemp, linseed or castor can be used to formulate bioresins, but achieving the mechanical, thermal and processing performance required for high value industrial applications often requires blending with synthetic components.

As a result, many commercially available technical bioresins contain up to 30 per cent bio derived content. CHCx3 partners are working to push beyond this limitation and develop fully bio based resin systems.

Bitrez is advancing fully bio derived thermosetting resins aimed at automotive and aerospace markets, where performance standards are particularly demanding. At the same time, Vital Acoustics is exploring 100 per cent bioresins within acoustic panel systems, combining environmental performance with sound absorption properties.

Employee owned UK manufacturer Scott Bader has developed Crestafire Bio P1-8001, a fully bio based resin derived from lignocellulosic sugar cane waste. It achieves EN45545-2 HL3, the highest fire performance rating for rail applications in Europe. Its strong fire, smoke and toxicity performance opens opportunities for biocomposites in safety critical environments such as public transport, aerospace and construction.

Innovation in Practice

Interest in natural fibre composites is growing rapidly. In 2022, BMW i Ventures invested in high performance natural fibre composites by acquiring a stake in Bcomp. Bcomp’s flax based reinforcement technologies, including powerRibs and ampliTex, are designed to substitute for carbon and glass fibre in specific applications. These materials offer lightweighting potential, vibration damping and improved impact behaviour, as they do not shatter in the same way as some synthetic composites.

As part of the CHCx3 project, Bitrez is also exploring the conversion of hemp seed oil into thermosetting resins tailored for biocomposites. These systems will incorporate hemp based textiles, contributing to the development of fully bio based composite materials.

In construction, BioTwin has developed hemp based composite wall studs designed to replace steel. These BioStuds have a significantly lower carbon footprint than conventional steel studs while offering strong fire resistance, durability and acoustic performance.

In infrastructure, Network Rail opened the FLOW Bridge in Shropshire in 2023. Manufactured by KS Composites, the 21 metre fibre reinforced polymer structure uses a combination of glass, carbon and flax fibres. It is substantially lighter than steel and was constructed off site to reduce installation time, transport requirements and associated carbon emissions.

In the automotive sector, Volkswagen has entered into cooperation with the German start up Revoltech to develop imitation leather made from industrial hemp residues. The material is fully bio based and designed for recyclability or composting at end of life.

A Rapidly Growing Market

The global composites market was estimated to be worth 117 billion US dollars in 2024 and is forecast to grow steadily to 2030. Growth is being driven by aerospace, automotive, construction, marine and renewable energy industries, all of which require lightweight, high strength materials.

The biocomposites sector has expanded even more rapidly. Global market value increased from 7.34 billion US dollars in 2012 to 24.63 billion US dollars in 2022. Continued growth is expected, driven by environmental awareness, regulatory pressures and corporate Net Zero commitments.

Even during periods of economic uncertainty, natural fibre reinforced plastics have continued to grow, reflecting sustained demand for lower carbon material solutions.

Functional and Sustainable Advantages

Composite materials offer strong sustainability benefits due to their high strength to weight ratio, thermal stability and corrosion resistance. Lightweighting in vehicles and aircraft reduces fuel consumption and energy use, contributing to decarbonisation.

Bio based composites provide additional advantages. Natural fibres such as flax can weigh significantly less than glass fibre, and their production can have a low or even negative carbon footprint because of carbon capture during crop growth.

Biocomposites also offer potential within a circular economy. Their natural composition creates opportunities for reuse, modular disassembly and, in some cases, industrial biodegradation. Acoustic performance is another strength. Hemp based materials, for example, provide excellent sound damping and vibration control in offices, studios and public spaces. They also deliver a natural aesthetic that synthetic fibres cannot replicate.

Innovation at the Cutting Edge

There remains substantial scope to advance fully bio based composite systems. Few 100 per cent bio based resins are currently available at industrial scale, and the full functional potential of different natural fibres has yet to be realised.

The CHCx3 project is supporting UK supply chains to develop innovative materials that combine performance, sustainability and regional sourcing. Policy drivers such as Extended Producer Responsibility regulations and Net Zero commitments are increasing demand for lighter, lower carbon alternatives in automotive, construction and packaging sectors.

The UK bio based composites market is still emerging but offers significant potential. With continued innovation, investment and policy alignment, biocomposites could play a central role in the transition towards circular, renewable and high performance material systems.