MEL Composites powers ZEN50 yacht with advanced composite materials
MEL Composites, a technology and materials supplier for the advanced composites industry, announces its role as the supplier of materials and consumables for the revolutionary ZEN50 yacht, designed by Julien Mélot. As the sole provider, MEL Composites supplied all components including carbon fabrics, vinylester resin, structural cores and ancillaries, along with comprehensive technical support throughout the project.
MEL Composites collaborated closely with the yacht builders. This collaboration included preparing test laminates to ensure the expected mechanical properties, assisting with mould preparation, and developing a precise resin infusion strategy. The company’s experts also led the infusion process, ensuring superior quality and maximum efficiency.
In addition to materials supply, MEL Composites provided pre-cut cores that contributed to significant weight savings, reduced waste, and enhanced geometric precision. The ZEN50 catamaran, powered by zero-emission solar and wind energy, utilises high-performance carbon fibre and structural foam core materials to achieve superior sailing performance while minimising energy consumption.
A key innovation in the construction was the integration of the outer skin, core, and inner skin in a single resin infusion process, with bulkheads and stiffeners fabricated separately and attached afterwards. This approach not only results in a lighter structure but also significantly reduces production waste.
Over a three-month period, the main hull sections of the ZEN50 were meticulously assembled in the mould, with approximately 800 kg of high-performance vinylester resin infused in just a few hours to complete the structure. MEL Composites’ technical expertise was critical in testing all materials, validating the lay-up, and ensuring the infusion stack met stringent standards before the final infusion, guaranteeing a robust and lightweight vessel.
Eduardo Galofre, CEO, MEL Composites, highlighted the company’s integral role in this pioneering project. “The ZEN50 exemplifies how design and materials can work together to deliver extraordinary performance. At MEL Composites, our mission was to provide materials optimised for the lay-up and infusion processes, and to support the builders – whom we recommended – during the crucial infusion stages,” Galofre stated. “ZEN Yachts is at the forefront of zero-emission marine technology, and we are excited to see the first hull take to the water soon.”
Cover photo: MEL Composites powers ZEN50 yacht (source: MEL Composites).
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