New Zealand-based sustainable materials developer Rubisco has partnered with advanced composites manufacturer Gurit to develop a lightweight composite sandwich panel that combines recycled, renewable, and natural materials for non-structural applications.
The collaboration was launched to create a composite solution with a lower environmental footprint while preserving the lightweight construction and design flexibility associated with conventional sandwich composites.
At the core of the panel is a combination of three material technologies: Gurit's recycled PET structural foam core, its AMPRO BIO bio-based epoxy resin, and Rubisco's BioTEX hemp fiber reinforcement. Depending on the selected material configuration, the finished panel can incorporate up to 100% recycled or bio-based content, providing manufacturers with a more sustainable composite alternative.
The material platform has also been designed for flexibility, allowing the panel's thickness, dimensions, fiber architecture, and overall construction to be adapted to meet different performance and application requirements.
By integrating recycled polymer foam, renewable resin chemistry, and natural fiber reinforcement into a single composite structure, the companies aim to provide a solution for applications where lightweight performance and improved material sustainability are key priorities.
The development reflects a broader industry trend toward incorporating circular and bio-derived raw materials into composite manufacturing. Sustainable sandwich structures such as this are gaining attention across sectors including marine, transportation, construction, and industrial equipment, where manufacturers are seeking to reduce material-related carbon emissions while maintaining practical performance.
The project demonstrates how recycled polymers, bio-based resins, and natural fibers can be combined into customizable composite structures, expanding the range of environmentally conscious material options available for future lightweight designs.