Materials, 2D-3D flattening and Processing, to optimize the topology and create breakthrough zero-waste Composite structural solutions

Introduction

Composite materials permit the reduction of weight at no compromise on mechanical resistance. Hence, they are selected for their performances and represent the selection of choice in all the applications where lightweight needs to be combined with high stiffness and rigidity.

Sustainability Concerns

Still, issues are raised on their sustainability, and heavy research efforts are spent on the recycling of composites, through the thermal route (pyrolysis) and the chemical route (solvolysis).

New Approach

A new approach to reach the sustainability target within the ZeroWasteLIFE project arises from achieving breakthrough performances in terms of waste avoidance, combined with a modular design for replacement and reuse of parts.

HV-TFP Process

The process of High Volume tailored fiber placement (HV-TFP) consists of three steps:

1. Stitching of multiple filaments on a flat pattern from 3D-2D flattening.
2. 2D-3D reconstruction of the final solid product through moulding.
3. Consolidation through autoclave or hot pressing.

Expected Outcomes

Thanks to the deposition of reinforcements only where needed, the project is expected to:

• Reduce waste.
• Improve material efficiency.
• Reduce costs for the final materials.
• Enhance their rate of reusability, thanks also to modular design.

The project outcome is validated through two different demo products: an automotive part and a part of a satellite, testifying to the advantages reached also in the aerospace sector, already optimizing the features of products.

Environmental Impact

A reduced net impact of 15% energy and CO2 emissions, and 40% raw materials will be demonstrated, leading to a strong impact on product acceptability. The overall sustainability is assessed through environmental, societal, and industrial-economic Life Cycle Assessment (LCA).

Long-term Expected Impacts

The project long-term expected impacts are:

• 18 GWh energy reduction.
• 30 k tons CO2 emissions reduction at the European level.

This will create a healthier world for EU citizens, thanks to direct exploitation at partner sites and licensing exploitation to unlock at the EU level the advantages generated.