UPSCALE is the first EU-project that has the specific goal to integrate artificial intelligence (AI) methods directly into traditional physics-based Computer Aided Engineering (CAE)-software and –methods. These CAE-tools are currently being used to develop road transportation not only in Europe but worldwide. The current focus of the project is to apply AI-methods to reduce the development time and increase the performance of electric vehicles (EVs) which are required by the automotive industry to reduce global emission levels. High performance computing (HPC) and CAE-software and –methods play a decisive role in vehicle development process. In order to make a significant impact on the development process, the two most HPC intensive CAE-applications have been chosen as use cases for the project: vehicle aero/thermal- and crash-modelling. When considering total automotive HPC usage, approximately 20% is used for aero/thermal simulations and up to 50% of HPC resources are utilized for crash simulations. By improving the effectiveness of these two areas, great increases in efficiency will lead to a 20% of reduction of product time to market. Other novel modelling approaches such as reduced order modelling will be coupled to the AI improved CAE-software and -methods to further reduce simulation time and ease the application of optimization tools needed to improve product quality. Through the combined effort of universities, research laboratories, European automotive OEMs, software companies and an AI-SME specialized in machine learning (ML), the UPSCALE project will provide a unique and effective environment to produce novel AI-based CAE-software solutions to improve European automotive competiveness.

PEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EPEACOC will showcase a first-of-a-kind economically and environmentally viable pre-commercial metallurgical system for recovering Precious Metals (PMs) (i.e. Platinum Group Metals (PGMs) identified as critical raw materials by the European Commission (EC), as well as gold (Au) and silver (Ag)), highly important for the EU economy, from a wide variety of abundant end-of-life (EoL) products in Europe. The concept is mainly based on previously developed recovery and refining technologies to TRL 5 in the PLATIRUS Research and Innovation project (Micro-Wave assisted leaching and Gas Diffusion Electrocrystallization GDEx), which were flagged by the Innovation Radar initiative of the EC as excellent innovations and showed a significant cost reduction and lower environmental impact compared to state-of-the-art hydrometallurgical processes as will be shown throughout the proposal. The PEACOC system will be demonstrated at pre-commercial scale at TRL7 with capacity to treat ~50t of PMs concentrates/year i.e., with a recovery capacity of i)2 kg PGMs/week from spent autocatalysts (containing ~2.5kg PGMs/t), ii) 0.5-1 kg Au/week from Printed Circuit Board Assembly (PCBA) with a focus on low and medium grade PCBA (containing 20-100 g Au/t) that are currently poorly valorized in industrial smelting processes due to low PM concentrations, and iii) 10 kg Ag/week from EoL Photovoltaic (PV) panels (containing ~3-10 kg Ag/t) which will be an abundant resource in Europe in the coming few years. The project will demonstrate the production of PMs at a profit margin up to 80% with respect to current PMs market prices.

Fatigue4Light project aims to investigate lightweight solutions adapted to the chassis part of EV to reach a 24-30% weight reduction. This will give a 12-15% weight saving from structural vehicle weight, and also increase EV safety due to reduced sprung mass. Solutions will be based on the introduction of especially developed material solutions with high fatigue performance (AHSS, stainless steel, Al alloys and hybrid metal-FRP materials), the development of new computer modelling with high fatigue prediction accuracy and new experimental methodologies that reduce the testing time. Sustainability of the proposed solutions will be continuously considered along project through an eco-design general approach. Environmental assessments through LCA, affordability based in LCC as well as social inclusion thanks to the recovery of CRMs from alternative waste streams will allow endowing Fatigue4Light into a novelty circular dimension. Attention will be given to manufacturing processes (cutting and welding) to improve the knowledge on their effect to the overall fatigue performance of chassis components. Six lab scale and industrial demonstrators will be defined to validate the proposed solutions. The fatigue model will be verified on demonstrators and then used in a virtual testing process to assess the weight reduction potential of the proposed materials, together with a redesign process oriented to lightweight the components while ensuring structural integrity. The project will reduce lead times to market due to the developed model and advanced fatigue testing methodologies and standardization will be followed. The final outcome is to give modelling and experimental tools for the lightweighting process on chassis parts subjected to fatigue. Clear and practical guidelines will be established with respect to different factors: eco design with proposed materials, advanced modelling approaches and the influence of forming processes on part performance.

The 2D Experimental Pilot Line (2D-EPL) project will establish a European ecosystem for prototype production of Graphene and Related Materials (GRM) based electronics, photonics and sensors. The project will cover the whole value chain including tool manufacturers, chemical and material providers and pilot lines to offer prototyping services to companies, research centers and academics. The 2D-EPL targets to the adoption of GRM integration by commercial semiconductor foundries and integrated device manufacturers through technology transfer and licensing. The project is built on two pillars. In Pillar 1, the 2D-EPL will offer prototyping services for 150 and 200 mm wafers, based on the current state of the art graphene device manufacturing and integration techniques. This will ensure external users and customers are served by the 2D-EPL early in the project and guarantees the inclusion of their input in the development of the final processes by providing the specifications on required device layouts, materials and device performances. In Pillar 2, the consortium will develop a fully automated process flow on 200 and 300 mm wafers, including the growth and vacuum transfer of single crystalline graphene and TMDCs. The knowledge gained in Pillar 2 will be transferred to Pillar 1 to continuously improve the baseline process provided by the 2D-EPL. To ensure sustainability of the 2D-EPL service after the project duration, integration with EUROPRACTICE consortium will be prepared. It provides for the European actors a platform to develop smart integrated systems, from advanced prototype design to small volume production. In addition, for the efficiency of the industrial exploitation, an Industrial Advisory Board consisting mainly of leading European semiconductor manufacturers and foundries will closely track and advise the progress of the 2D-EPL. This approach will enable European players to take the lead in this emerging field of technology.