FEATURE MATERIALS IN DESIGN & PROTOTYPING
Fibre-based materials from BComp are
enabling manufacturers to build high
performance vehicles without compromising on sustainability requirements
B
comp’s proprietary natural fibre-based reinforcement materials – ampliTex and powerRibs – are helping to decarbonise
manufacturing and reduce environmental impacts while enabling lightweight performance and extensive design freedom in a wide range of high- performance applications. Its flax- based composites use 50% less fossil-basedmaterial and are said to be up to 40% lighter than the traditional plastics they replace. Recently, the company announced a partnership with Polestar, where its ampliTex and powerRibs technologies have been used in the front seatbacks and tailgate structure of the Polestar 5. The Polestar 5 GT delivers up to 650 kW (884 hp) and 1,015 Nm of torque, with aWLTP range of up to 678 km. Its 800V electrical architecture and 350 kW DC charging capability allows the battery to charge from 10% to 80% in as little as 22minutes. Together, the companies developed a bespoke
ampliTex flax fabric known as the ‘Polestar SignatureWeave’, which serves both structural and aesthetic functions in the interior cabin. Polestar has published full lifecycle
assessments (LCA) across its vehicle range since 2020. These cradle-to-gate assessments account for emissions generated from raw material extraction through to vehicle manufacturing, providing a transparent benchmark for future reductions. According to the company, the Polestar 5 carries a cradle-
to-gate carbon footprint of 23.8 tonnes of CO2 equivalent (tCO2e) per vehicle.
MATERIALS IN THE DESIGN The Polestar 5’s front seatbacks combine Bcomp’s core ampliTex and powerRibs technologies with natural fibre polypropylene (NFPP). ampliTex is a reinforcement fabric woven from European flax fibres that are processed mechanically, reducing the energy and emissions intensity compared with synthetic alternatives like carbon fibre or glass-reinforced plastics. powerRibs is a proprietary three-dimensional
reinforcement grid made from flax, inspired by the vein structure of leaves. Applied to the rear of a panel, it increases bending stiffness, allowing the component to be made thinner and lighter without sacrificing structural integrity. The visible finish inside the vehicle is Bcomp’s
46 DESIGN SOLUTIONS OCTOBER 2026
The SUZUKI CN CHALLENGE GSX-R1000R features elements made from natural fibre composites
The Polestar 5
2026 Team SUZUKI CN CHALLENGE GSX-R1000R was different. Its fairings, wings and other aerodynamic elements weremade fromBcomp’s race-proven innovative natural fibre composites, which remained unpainted to showcase the natural colour of the flax within. The 2026 Team SUZUKI CN CHALLENGE GSX-R1000R uses ampliTex and powerRibs for the front and rear fenders, side fairings, seat fairing, and winglets. It is the result of a collaboration that began in 2024 between Team SUZUKI CN CHALLENGE, Tras (a Japanese composites expert), and Bcomp. Natsumi Nitta, general manager at Tras,
Polestar SignatureWeave, a two-tone material that functions as both a structural element and a design surface, removing the need for added decorative layers. The Polestar 5’s tailgate structure also incorporates powerRibs technology. All Bcomp components used in the vehicle
have been validated to meet stringent automotive standards for durability, safety, UV resistance, scratch resistance, and long-term ageing performance. Unlike conventional carbon fibre composites,
which are typically landfilled or incinerated without energy recovery at the end of their service life, Bcomp’s flax-based materials offer more practical end-of-life pathways. Production scraps can be recycled into materials for injection moulding applications, and thermoset flax composites can be incinerated for energy recovery, helping recover value from the biogenic carbon stored in the material. Commenting on the use of the materials, Maria
Uggla, head of CMF design at Polestar said: “The materials we use in our vehicles are important from their environmental impact as well as their performance aspects. With the Polestar 5, we aim for a performance-focused Grand Tourer, without compromising on our sustainability targets. Bcomp’s materials have allowed us to build a performance-focused seatback as well as not compromise our sustainability requirements.”
RACE PROVEN MATERIALS Amongst the field of conventional race bikes at the 47th ‘Coca-Cola’ Suzuka 8 Hours this July, the
explained: “Each year we have expanded the use of Bcomp’s technologies on the bike, making best use of its excellent stiffness, light weight, and vibration-damping properties. Most importantly, it
cuts CO2 emissions by up to 85% versus carbon fibre with expanded ‘end-of-life’ options, which aligns with the mission of Team SUZUKI CN CHALLENGE. The race bike highlights the experience and expertise we have developed in producing parts with Bcomp’s technologies, enabling Suzuki to thoroughly test them in the harsh conditions of motorsport.”
HIGH PERFORMANCE Rather than simply replacing the carbon parts, Tras worked with Bcomp to refine the designs in detail. This included developing an improved prepreg system that was better suited to the hot and humid conditions of Southeast Asia. Last year, the Team SUZUKI CN CHALLENGE GSX-R1000R had a crash during the race in which the centre cowl sustained significant damage. Unlike carbon fibre, which shatters, Bcomp’s technologies have ductile failure behaviour – in this case, the cowl cracked but continued to hold its shape thanks to the powerRibs. Alongside sustainable composites, Team
SUZUKI CN CHALLENGE has also adopted sustainable fuel, tyres with recycled material, bio-sourced engine oil, an eco-friendly titanium exhaust, and team kit made from recycled fabric. Going forward, Suzuki and Tras have begun
testing Bcomp winglets in the All Japan Road Race Championship (JSB1000 class).
BComp
www.bcomp.com
www.designsolutionsmag.co.uk
SUSTAINABLE DESIGNS
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