Outstanding Composite Solutions for Modern Railway Interiors
In close partnership with MÁV-START Zrt., Carbon Composites plays a key role in modernising the Hungarian InterCity fleet. Since 2015, we have supplied cutting-edge interior passenger seat elements for more than 90 refurbished coaches in the prestigious IC+ series.
Our mission in the railway sector is to bridge the gap between lightweight innovation and uncompromising safety. Our solutions guarantee “vandal-resistant” durability while fully complying with the strictest European railway standards, including EN 45545-2 (HL2/HL3 rated) fire protection and ISO 9001:2015 quality management requirements.
Technical Specifications and Expertise
Throughout the project, we employ the most advanced manufacturing technologies. The seat side panels are produced using RTM and PU-RIM foaming technology with sandwich construction, incorporating integrated armrest hinges. The flame-retardant glass fibre (GFRP) seat structures weigh approximately 6 kg each, significantly contributing to the reduction of the train’s overall energy consumption.
The excellent strength-to-weight ratio is achieved through the use of PUR rigid foam cores (sandwich construction). The manufacturing process is made exceptionally precise and efficient through in-house CNC machining and the use of heated aluminium moulds.
MÁV-START Reference Summary
To date, we have equipped 92 IC+ series coaches with our custom-made components. We supply 52 seat bodies per coach, specifically designed for intensive daily use. The result is a truly vandal-resistant structure: engineered and optimised through finite element simulations (FEM), the design is exceptionally resistant to physical impacts and blows.
Carbon Composites offers complete turnkey solutions, from finite element modelling to tooling design. Multi-split, heated aluminium mould structures ensure short cycle times and outstanding productivity. With in-house tooling manufacture, PU-RIM sandwich cores, GFRP part production, and structured painted surface finishing, all competencies are concentrated under one roof.