BioStruct | Manufacturing process for bio-based fibre-reinforced composite parts for structural applications

Summary

Currently, the use of bio-composites is limited to less critical applications that do not have significant requirements in terms of mechanical performance. However, the use of synthetic composites made from carbon or glass fibre has several difficulties in terms recycling and in terms of dependence on third countries. About 98% of these synthetic composites still end up in landfills and about 80% of the raw materials are currently manufactured outside of Europe. To improve this situation, the project addresses the challenges of using bio-composites for structural parts and aims to increase the range of applications in which bio-composites can be used.

This will be achieved by developing an accurate draping process to control fibre orientation, by creating material models that capture the natural variability of the material and by integrating nano-structured, bio-based sensors for load monitoring. Through the increased accuracy and additional control loops in the manufacturing process the consortium expects to achieve predictable properties and constant quality.

Within the project use cases from wind energy and boat-building will be investigated, aiming at the manufacturing of a full size rotor blade and a ship hull to demonstrate the technical feasibility and achieving TRL7 for the manufacturing technologies. In addition to the end users, the consortium consists of partners from automation, machine building, measurement technology, material manufacturing and simulation software to cover all aspects of the developments. Based on the predicted growth of the bio-composites market, which is expected to increase by a factor of 2.5 by 2030, the consortium expects a market potential of about 100M€ by 2030.

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More information & hyperlinks
Web resources: https://cordis.europa.eu/project/id/101136335
Start date: 01-01-2024
End date: 31-12-2026
Total budget - Public funding: - 5 476 221,00 Euro
Cordis data

Original description

Currently, the use of bio-composites is limited to less critical applications that do not have significant requirements in terms of mechanical performance. However, the use of synthetic composites made from carbon or glass fibre has several difficulties in terms recycling and in terms of dependence on third countries. About 98% of these synthetic composites still end up in landfills and about 80% of the raw materials are currently manufactured outside of Europe. To improve this situation, the project addresses the challenges of using bio-composites for structural parts and aims to increase the range of applications in which bio-composites can be used. This will be achieved by developing an accurate draping process to control fibre orientation, by creating material models that capture the natural variability of the material and by integrating nano-structured, bio-based sensors for load monitoring. Through the increased accuracy and additional control loops in the manufacturing process the consortium expects to achieve predictable properties and constant quality.
Within the project use cases from wind energy and boat-building will be investigated, aiming at the manufacturing of a full size rotor blade and a ship hull to demonstrate the technical feasibility and achieving TRL7 for the manufacturing technologies. In addition to the end users, the consortium consists of partners from automation, machine building, measurement technology, material manufacturing and simulation software to cover all aspects of the developments. Based on the predicted growth of the bio-composites market, which is expected to increase by a factor of 2.5 by 2030, the consortium expects a market potential of about 100M€ by 2030.

Status

SIGNED

Call topic

HORIZON-CL4-2023-TWIN-TRANSITION-01-02

Update Date

29-01-2024
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Factories of the Future Partnership - Made in Europe Partnership

Made in Europe (MiE)
HORIZON-CL4-2023-TWIN-TRANSITION-01
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
MiE_25-27_RP03: Recovering and preserving the European leadership in strategic and high value added products
MiE_25-27_RP03_PastCallTopics(main)
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
MiE_25-27_RP04: Circular, connected manufacturing ecosystems
MiE_25-27_RP06: Manufacturing with new/ limited raw materials availability
MiE_25-27_RP15: Bio-intelligent Manufacturing
Specific Objective 1: Excellent, responsive and smart factories & supply chains
R&I Objective 1.3: Zero-defect and zero-downtime high-precision manufacturing, including predictive quality and non-destructive inspection methods
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
R&I Objective 1.5: Advanced Manufacturing processes for smart and complex products
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
R&I Objective 1.6: Manufacturing for miniaturisation and functional Integration
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
Horizon Europe
HORIZON.2 Global Challenges and European Industrial Competitiveness
HORIZON.2.4 Digital, Industry and Space
HORIZON.2.4.0 Cross-cutting call topics
HORIZON-CL4-2023-TWIN-TRANSITION-01
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)
HORIZON.2.4.1 Manufacturing Technologies
HORIZON-CL4-2023-TWIN-TRANSITION-01
HORIZON-CL4-2023-TWIN-TRANSITION-01-02: High-precision OR complex product manufacturing – potentially including the use of photonics (Made in Europe and Photonics Partnerships) (IA)