As part of Ayats’ commitment to reducing vehicle weight in line with evolving EU legislation, the new foam sandwich composite window frame covers, developed with MEL Composites’ support, are up to 80% lighter than the traditional foam elastomer alternatives. This significant reduction in weight contributes directly to increased passenger capacity and greater overall efficiency.

Carrocerías Ayats, based in Arbúcies (Girona), is a long-standing leader in the design and manufacture of double-decker buses and coaches, operating in over 20 countries. With a history of innovation, including being the first European manufacturer to achieve the r.66 tilt test certification for double-decker vehicles, Ayats continues to push the boundaries of vehicle design and performance.

While traditionally focused on steel and aluminium structures, Ayats saw a unique opportunity in its recent acquisition of Karbon Design, a Barcelona-based carbon padel racquet manufacturer. MEL Composites has supported Karbon Design for over a decade, developing efficient manufacturing techniques that scaled alongside the sport’s popularity. This foundation proved invaluable when adapting processes for automotive-scale applications.

The project began with the analysis of eight window frame cover components, two of which were selected for composite development. MEL engineered bespoke tooling, including aluminium and tooling board moulds, and innovatively combined two distinct parts into a single mould to increase manufacturing efficiency. Initial parts were produced using resin infusion with both solid laminate and 1mm Rohacell Rohacryl cored sandwich structures - the cores sliced in-house at MEL Composites – resulting in foam sandwich composite window frame covers that are 80% lighter. As volumes grow, production is expected to transition to light RTM and press moulding methods.

Throughout the collaboration, MEL Composites provided critical technical input, suggesting improvements in part design, tooling surface quality, and manufacturing workflow, guiding Ayats toward a more automated, cost-effective, and scalable production process.

“This project is a testament to how proven composite technologies from other sectors, like sporting goods, can be adapted to meet the unique challenges of the automotive industry,” said Eduardo Galofre, CEO of MEL Composites. “It has been a pleasure working with Carrocerías Ayats to develop components that are lightweight, low-risk, and suitable for future automated production. We’re excited about the potential for further collaboration and expanded composite integration in their next-generation vehicles.