Barcelona-headquartered MEL Composites was the sole supplier of materials and consumables for the new ZEN50 yacht designed by Julien Mélot, including carbon fabrics, vinylester resins, structural cores and ancillaries, along with providing comprehensive technical support throughout the project.

MEL collaborated closely with the yacht builder by preparing test laminates to ensure the specified mechanical properties, assisting with mould preparation and developing a precise resin infusion strategy. The company’s experts also led the infusion process.

Pre-cut cores that contributed to significant weight savings, reduced waste and enhanced geometric precision were also supplied. 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 800kg of high-performance vinylester resin infused in just a few hours to complete the structure.

“The ZEN50 exemplifies how design and materials can work together to deliver extraordinary performance,” said MEL CEO Eduardo Galofre. “Our mission was to provide materials optimised for the lay-up and infusion processes and to support the builders during the crucial infusion stages. ZEN Yachts is at the forefront of zero-emissions marine technology, and we are excited that the first ZEN50 will take to the water soon.”

www.melcomposites.es