Discovery Technologies Ltd, based at Baltic Wharf, Totnes, is developing new sustainable technologies and materials for the marine sector, including unmanned surface vessels (USVs) and sailing yachts.
The use of materials and the whole process of constructing marine vessels represents a substantial proportion (more than 80% of greenhouse gas emissions in the build are associated with the use of composite materials, most notable is virgin carbon fibre - source IMOCA.org/11th Hour Racing LSA report) of the whole environmental impact a vessel poses throughout its lifetime. The first life cycle assessments that research and calculate the overall impact on the natural environment as caused by pleasure boats, indicate that it is the use of non- recyclable materials rather than the use of fuels that is the largest source of pollution caused by boats. For the marine sector to evolve into a net zero industry, the use of sustainable materials needs to be addressed.
Most vessels (including uncrewed marine vessels) under 120 feet in length are manufactured by glass reinforced plastic (GRP) composites. The process of manufacturing GRP is both energy intensive and uses a number of chemicals and materials which are harmful to the environment. GRP also has limited commercial scale recycling options and economic viability is challenging. The industry usage of GRP is annually increasing by at least 10%.
The Discovery Technologies team has been working in collaboration with a number of industry partners to develop a new high performance mineral-based fibre material system called D-COMP.
D-COMP is a sustainable high performance material (HPM) replacement for glass fibre. Unlike glass fibre, D-COMP fibre can be commercially recycled to 100% of its original properties, and its mechanical properties are more than 30% higher than GRP, which means less material can be used for a given design load case.
The D-COMP fibre system can also be remelted and new fibres created. D-COMP also has better thermal properties, acoustic and impact resistance. D-COMP can be used in the same component manufacturing processes such as wet layup, vacuum resin infusion and resin transfer moulding as glass fibre.
The combination of the mechanical properties and the environmental impact of the fibre manufacturing process will result in a 75% reduction of CO2 by using D-COMP.
This project is an important step in the journey of 'Clean Maritime', and once approved for marine use, Discovery Technologies will look to roll it out across the wider marine segment.