Composites Materials

Revolutionising post-3D printing treatments through the use of the DryLyte technology. DryTi3D research, studies and demonstrates strategies to obtain Ti6Al4V parts with improved surface quality in additive manufacturing for the biomedical and aerospace industries, optimising the dry electropolishing process. The project investigates a design of new solid-state electrolytes (with different electrolyte particle size, acid media and concentration), electrical parameters and polishing strategies to offer greater profitability and efficiency to the process. Dry electropolishing surface finishing process is proposed to be the most efficient surface treatment to produce mirror-like workpieces with tailored surface and near surface characteristics. [...]

Highlighting the lack of recycling of auxiliary materials used in the composite production. IMPLICIT develops a circular economy system for the recycling of auxiliary materials such as vacuum bags, breather fabrics and bleeding cloths, using a combination of mechanical, physical and chemical recycling methods to recover the original polymers. Despite advances in the recycling of the composites themselves, these auxiliary materials are primarily disposed through landfill or incineration. This poses a significant challenge to achieving the European Union's 2030 recycling targets. IMPLICIT seeks to close the life cycle of these auxiliary materials by reintroducing the recovered [...]

Breaking frontiers in sustainable and circular biocomposites with high performance. BIOntier creates an industrial platform to develop the new generation of multifunctional, sustainable, and recyclable bio-based composites (BioC) with enhanced properties for sectors such as automotive, aerospace, energy, and water treatment. The project promotes advanced manufacturing processes, improving synthesis and stability while reducing environmental impact. The initiative aligns with the UN Sustainable Development Goals and the EU Green Deal. BIOntier also fosters collaboration and establishes networks to tackle environmental challenges, demonstrating high-level industrial applications and opening new opportunities for BioC adoption in European industries. The global [...]

Disruptive carbon-fibre sternal closure system for fast and secure fixation of a sternotomy. CarbonSC develops and clinically tests a disruptive sternal closure compatible with mini-sternotomies that solves the main drawbacks of current technologies. In this sense, CarbonSC is the first cost-effective solution that fixes the sternum in a safe, fast and error-proof way, while avoiding bone damage. The main clinical innovations of the CarbonSC system are, on the one hand, designing a unique mechanism, integrated into the device itself, that ensures the application of a precise tightening force to close the sternum, and on the other [...]

Towards a more sustainable future with biobased vitrimeric resins. BioVit develops vitrimeric resins from natural resources for the production of high-performance composite materials, offering sustainable solutions for industry. Vitrimers combine the mechanical properties of thermoset polymers at low temperatures with the malleability of thermoplastic polymers at high temperatures, allowing not only their use in advanced applications, but also their reuse or recycling at the end of their useful life. BioVit adapts the synthesis of vitrimeric resins to produce large batches suitable for the manufacture of composite material parts on an industrial scale. This adaptation ensures that [...]

Type III compressed hydrogen tanks for collective mobility using high-cadence processes. H3MOV develops high-cadence production processes to provide innovative solutions for compressed hydrogen storage, to address the high cost and low efficiency of current manufacturing methods. The project focuses on type III compressed hydrogen tanks, which, although not the lightest for a given volume, have several advantages over type IV tanks, such as lower hydrogen permeability and simpler sealing systems for the tank nozzles. Due to their slightly higher weight, these tanks are currently used in collective mobility vehicles, such as buses and trains. H3MOV focuses [...]

Turning agri-food waste and biomass into sustainable polymers. The Polymers-5B project develops novel alternative biological polymers synthesized from biobased monomers sourced from underexploited second-generation feedstocks, such as agri/food waste and biomass, obeying the food first and cascading principle. Polymers-5B brings together cutting-edge technologies and knowledge to develop and drive innovation in biocatalysis and green chemistry processes, generating novel bio-based polymers like polyesters and polyamides with pendent functional groups (e.g. hydroxy, carboxylic, amine, epoxy, thiol, etc.), polyphenols and polyfurans, which mimic fossil-based polymers properties, targeting improved biodegradability. These new polymers will be blended to provide valuable bio-composites [...]

Creation of a cyber-physical device that monitors and optimizes the plastic injection process. The DASIT project develops a cyber-physical prototype that allows real-time and remote monitoring of the injection process, obtaining direct data from sensors embedded in the mould and indirect data through a device connected to the mould. The device powered by DASIT is energy efficient, by integrating an energy harvesting system, and has a geolocation system through the implementation of advanced technologies to track the location of the molds. It is a cloud-connected wireless device with a low-cost approach. In addition, data quality validation [...]

Development of new biodegradable plastic formulations for the biomedical sector. The PHASAL project develops different bioplastic formulations that introduce PHB-HV with different loads of hydroxyvalerate (-HV) from the revaluation of organic waste. The objective is that these formulations, applicable to the health field, present advanced biodegradability and biocompatibility properties to minimize the environmental impact they present due to their poor recyclability. In this sense, PHASAL develops a complex rigid packaging system, such as a suture kit, and a direct medical application with controlled drug release, such as a transdermal patch. The new advanced formulations developed during [...]

Pioneering sustainable solutions based on graphene to address environmental challenges. The GIANCE project establishes a holistic, integrative and industry-driven platform with a clear focus on the improvement of sustainable materials and their real-world applications. In this sense, GIANCE designs, develops and scales the next generation of multifunctional composites, coatings, foams and membranes based on graphene and derived materials (GRM), so that they are profitable, sustainable, lightweight and recyclable. These advanced materials are designed to improve their performance, such as their thermal, mechanical and chemical properties, offering functionalities such as wear resistance, corrosion resistance, chemical and fire [...]

Design, manufacture and experimental validation of a tank to store hydrogen at high pressure. The HIDROGENIA project develops and validates to TRL 5 a type IV tank to safely store hydrogen at high pressure (700 bars). These types of tanks are already manufactured today, but they present permeability problems because the materials used do not have a sufficient barrier effect against hydrogen passage. Eurecat participates in the HIDROGENIA project through different Technological Units: The Product Development & Multiphysics Simulation Unit designs the interior liner and calculates the tank based on the numerical simulation of the different elements of [...]

Improvement of shaping systems for the deposition of semi-molten materials, applicable mainly to plastic, metallic or mixed materials (plastic, metallic, ceramic and inorganic). The FUSE3D project develops new technologies for the deposition of semi-molten material with the aim to improve the adhesion between layers of material and increasing its strength, combining different materials when printing to obtain different surfaces and be able to create geometries with more height. The innovation promoted by the project allows to carry out studies, characterisations and optimisations of printing materials and processes. Moreover, the definition of the mechanical properties of the [...]

New manufacturing process that allows to use high-performance thermoplastic matrix composite materials reinforced with carbon fibre in the regional aircraft construction. The utilization of these thermoplastic matrix composite materials in the construction of regional aircrafts is limited due to the complexity of forming of these materials and the high costs that the process implies. The KEELBEMAN innovation reduces these production and assembly costs through the optimisation of the high temperature compression process and the application of innovative welding technologies, enabling the use of these materials in the construction of structures for regional aircrafts. KEELBEMAN solves technological [...]

Development of regional aircraft thermoplastic composite windows frames using advanced and innovative industrial processes and Out of Autoclave composite manufacturing (OOA – alternative to autoclave process commonly applied for the aeronautic industry for producing high performance composite materials) with the aim of reducing the weight of the window frames and their production costs. WINFRAME 4.0 solution allows the utilization of thermoplastic composite materials for the construction of regional aircrafts and develops faster and more reliable processes, thanks to the use of polymers reinforced with carbon fibres and innovative processes. The innovations of WINFRAME 4.0, coordinated by [...]

New manufacturing process for carbon fibre fuselage frames to be able to apply these materials in the construction of regional aircrafts. The new manufacturing process developed by COFRARE 2020 marks a new milestone for the aeronautical European industry and for the construction of lighter and more sustainable planes, through the integration of carbon fibre into the fuselage. These materials, which are already being used for the construction of big commercial aircrafts’ structure, imply high costs, which complicates its integration in smaller airplanes. COFRARE 2020 solution improves the manufacturing flow and reduces significantly the manufacturing costs and [...]