INN-PAEK will face the industrial production of the PAEK-based Flange Wheel for the electrical environmental control system by applying the 5Ms injection window process developed, validated and optimised by AITIIP over the last 25 year for transferring complex metallic parts to lightweight polymeric components. The 5Ms injection window process starts Modelling the bests solution, combining i) rheological, kinematic and mechanical simulation, ii) validation (coupons and specimens) tests and iii) optimisation algorithms to select the optimal Material formulation and its transformation process as well as the Mould geometry and the required innovations. In INN-PAEK, this process will be also based on the capacity of the additive manufacturing technologies to produce complex moulds that will modify its geometry during the transformation process to get properly adapted to complex geometries. Finally, the 5Ms injection window process includes destructive (mainly mechanical) and non-destructive (tomography) tests to check the right Manufacturing of the polymeric part, allowing to implement the required modifications in the mould and feeding the Machine learning phase, based on optimisation algorithms generated in previous research and innovation projects. The machine learning phase will also consider the information captured from the technician experience, the dedicated in process sensors (rheological sprue) implemented in the injection machine and the LCA and LCC analysis of the final parts. This process has been already successfully used by AITIIP with complex parts for automotive, urban furniture or medical applications among others. INN-PAEK will demonstrate the production of flange wheel with a cost reduction by 30%, a weight reduction by 40% that implies a CO2 emissions reduction by 30 during the operation phase as well as a 20% reduction during the manufacturing process.

The main objective of the FALCON project is the design and manufacturing a versatile tooling system (reduction of tooling by up 40%) for the effective (30% reduction in time, 20% in cost and 20% in energy) and high quality (Aeronautic Quality Standards) production of CFRP frames for different fuselage sections subjected to different level of loads. The FALCON system will include two interrelated components (press-forming tooling and curing tooling) which will be supported through laser tracker technologies and robotic positioning/placement equipment. The press-forming tooling consists of flexible and adaptable modules designed for different frame geometries that will increase the number and typologies of produced parts. These modules have plug and produce connectors for fast and accurate connexion and individual hydraulic cylinders for a precise controlling of the kinematics of the process. In addition, the cooling/heating system will be also especially designed for improving part quality and process energy efficiency. This cooling/heating is adapted to part geometries through the combination of metallisation technologies with embedded channels and metallic additive 3D technologies applied to trickiest geometries. In other hand, the curing tooling is designed for including all the required reinforcements into the frame during the curing process independently to the face of the part in which should be placed. This will be achieved by means of positioning tooling which are produced according to each part requirements through the utilisation of high accuracy mechanising equipment. Finally, the process is continuously controlled and optimised thanks to a real time monitoring system in order to be robust and repeatable. The monitoring system is feed through integrated sensors (strain and temperature gauges) and external equipment (laser tracker) in order to obtain soundness data related to deformation, displacements and temperature at micro and macro levels.

The overall objective of HERON is to develop and manufacture a comprehensive set of innovative, cost-effective and sustainable tooling for RTM processes as well as the use of high deposition rate ALM technologies, aiming at improving the energy and resource efficiency of the manufacturing of a leading edge and trailing edge for integration on aeronautical demonstrator. To this end, four innovative technologies will be combined and demonstrated at operational environments in aeronautic sector reached TRL 6: A. Modular design for RTM tooling to facilitate leading edge parts demoulding and heating strategies, combining different heating systems in customized surfaces. B. Near real time process monitoring as path to control RTM process parameters (such us temperature) relying on in-mould sensors (thermocouples, strain and pressure gauges), external gauges (thermal cameras) and a control algorithm for thermal distribution. C. High deposition rate hybrid ALM for trailing edge production to reduce resources consumption, using resins specifically developed for aeronautical applications. D. Finally, a fully automated and high accuracy production environment for the manufacturing of the necessary tooling for the leading edge and the application of the ALM technologies for the trailing edge, could ensure an accurate integration on the hybrid laminar wing demonstrators and an easy reparation or modification of the RTM tooling and ALM parts These four innovative approaches can lead up to a direct 25 % of energy consumption reduction, 20 % of cost reduction and 30 % reduction in time cycle for the production of aeronautical structures. The project concept will address 100% tooling needed in the RTM and ALM processes, both for manufacturing and validating purposes, leading to a reduction of CO2 equivalent emission by up 30% linked to the Clean Sky 2 Programme High-level Objectives.

New strategies of the European Union related with transition to bio-based and circular economy involve several sustainability requirements, among others, at the environmental level. In this context, the project Bio-Uptake targeted the development of bio-based polymers with innovation towards circular solutions, promoting the re-use of the products to be developed (bath ceiling, foot orthosis, garbage lid). In Bio-Uptake-Hop-On, UAveiro brings to Bio-Uptake, a new pillar to fully achieve the environmental sustainability of the developed products, by certifying their low environmental and human impacts. Thus, Bio-Uptake-Hop-On main goal is to characterize the safety of developed bio-based materials and products to Environmental and Human (E&H) Health, across the different production and innovation steps. For this, three fit-for-purpose approaches will apply: i) assess the E&H hazardousness of the materials and products, to support applying the safe-by-design concept and select the least hazardous materials and intermediate product formats to proceed to the final production stage; ii) identify the best architecture design of foot orthosis and bath ceiling formats that promotes less growth of human pathogens, and (iii) characterize the influence of weathering conditions, during usage, on chemicals/particles leakage from the garbage lid and as well on its safety to the environment. The applied research carried out within Bio-Uptake-Hop-On will generate a complementary indicator that will benchmark the toxicity of developed materials and products to feed the Life Cycle Assessment to be carried out in WP1 and will assist WP5 on the selection of the bio-based materials and products that are more eco-friendly and safer for Humans, while keeping their functionality. By contributing to the development of materials and products with lower environmental and human impacts Bio-Uptake-Hop-On will support achieving Green Deal targets, namely those related with Zero pollution.

ECO-CLIP project aims to demonstrate the technical, environmental and economic feasibility of manufacturing structural parts of aircrafts, specifically frame clips and system brackets, using recycled CF/LMPAEK obtained from factory waste. The overall approach of ECO-CLIP is to develop a short fibre recycled composite based on CF/LMPAEK, the manufacturing process for fabricating structural parts of aircraft (clips and brackets) and the welding technology for a success joining in a fuselage demonstrator avoiding fasteners. The whole product development process and manufacture technology will be validated by LCA/LCC studies. As final result, the new manufacturing processing route will be demonstrated as cost-effective and environmentally favorable by LCA and LCC studies. This can be understood in different stages: • Designing of recycling route to re-use material from factory waste • Material development: exploring different mixtures of %wt recycled %wt virgin CF/LMPAEK to accomplish the structural and mechanical requirements. • Design of manufacturing processes fulfilling the use case scenarios (clips and brackets) • Selected the joining technology for a MFFD • Assessment of developed technology through a study of ecological and economical impact The innovation results from ECO-CLIP project will comprise: development of a new composite material based on short fibre recycled CF/LMPAEK, optimised for injection moulding and 3D-printing, and methodology to redesign structural parts to be installed on a MFFD. These solutions will enable to validate the assessment of the technology, and the viability of the environmental and economical impact.