One of the key players in this project is FORVIA, the world’s 7th largest automotive technology supplier. Aware of its environmental responsibilities, the company is committed to reducing its greenhouse gas emissions and minimising its environmental footprint, while complying with the legal requirements of the European Union. For FORVIA, participating in FIBIAS++ is perfectly aligned with its ‘Net Zero Emissions’ strategy.

With the rise of electric vehicles, reducing vehicle weight is a priority, particularly for manufacturers such as STELLANTIS, a partner in the project, which has made a commitment to be carbon net zero in 2038.  Thermoplastic composites are becoming an essential alternative to thermoset composites and metallic materials in the manufacture of automotive components, but the challenge lies in the very nature of this material. Can we produce a more environmentally sustainable composite, and integrate it into an environment of metal parts, while maintaining sufficient mechanical performance to meet strict safety requirements? This is the central question that FIBIAS++ is seeking to answer.

FIBIAS++: Cleaner and more sustainable composites

The FIBIAS++ project is the continuation of an initial research project that focused on developing technologies for processing thermoplastic composites. This second phase adds an environmental dimension, with the aim of developing composites with a low CO2 footprint and incorporating recycled materials, while maintaining high performance for semi-structural and even structural automotive applications.

The project teams are working on composites such as organosheets (*), GMT (Glass Mat reinforced Thermoplastics) and sandwich structures. The major challenge is to incorporate recycled materials such as PET. The environmental benefits are considerable: these thermoplastic composites could reduce CO2 emissions by 50% compared with traditional materials such as steel or thermoset composites. In addition, such an innovation offers a material with a high recycled content that has similar mechanical properties to equivalent materials of non-recycled quality.  This makes it possible to develop parts with a weight saving of 30 to 35% compared with metal structures, which is a key factor in lightening electric vehicles and optimising their autonomy, as well as reducing the CO2 footprint and incorporating recycled content.

Recycling at the heart of the process

One of the innovative aspects of FIBIAS++ is the recycling of post-consumer and post-industrial waste. IMT Nord Europe, a key partner in the project, has focused on the manufacture of PET film from recycled materials, such as crushed plastic bottles. These recycled materials are then incorporated into thermoplastic composite products or semi-finished products. IMT Nord Europe also assessed the effects of the shredding process on the performance of the materials, as the aim is to maintain optimum mechanical properties throughout the recycling cycle.

At the same time, the IRT Jules Verne has developed a specific low-shear mixer for directly recycling composites scrap and offcuts. This equipment mixes the waste to produce a homogeneous molten dough that can be reused by stamping or thermocompression to form finished parts or assemblies with metal parts. This innovation could be particularly promising for industrial production lines, where it would make it possible to avoid complex and costly subsequent processing of waste, while reducing transport and the costs associated with external recycling.

A promising collaboration for the future of the industry

The FIBIAS++ project represents a major step forward for the automotive industry, but also for other sectors that could benefit from these innovations. Thanks to the joint efforts of the IRT Jules Verne, FORVIA, STELLANTIS, IMT Nord Europe and CMO (a mould maker in the composites sector), concrete solutions are being developed to reduce the environmental impact while preserving the performance of the materials.

The results are encouraging and pave the way for the wider integration of recycled thermoplastic composites in various industrial sectors. In addition, the mixer developed by the IRT could find applications in other sectors where waste management is a major issue.

Towards a more sustainable future

The FIBIAS++ project marks an important step towards the ecological transition of the automotive industry. By using recycled materials while maintaining high quality standards, this project provides a concrete response to current environmental challenges. The collaboration between the various partners has enabled the development of innovative technologies with applications that go beyond the automotive sector and could be of use to other industries that are sensitive to the need to optimize resources.

‘The future of this project could see new developments in the use of recycled composites, and further strengthen the circular economy dynamic in industry. FIBIAS++ is a fine illustration of how technological research and innovation can contribute to a more sustainable world,’ concludes Céline Constantin, project manager at IRT Jules Verne.

(*) an organosheet is a consolidated multi-layer prepreg or semi-preg sheets made of carbon or glass fibre fabrics and thermoplastics

Cet article FIBIAS++ : How recycled thermoplastic composite is revolutionizing the automotive industry est apparu en premier sur IRT Jules Verne.

Overview of the CARBO4POWER Project

To recap, the CARBO4POWER project aimed at developing innovative technologies for the manufacturing of marine energy system components, such as wind and tidal turbines, using advanced composite materials. These innovations were designed to address several key challenges: reducing production costs, improving the mechanical performance of components, and decreasing their environmental impact.

The project focused on multiple areas, including the development of new composite materials, optimized manufacturing processes, and the integration of structural health monitoring solutions to enhance the durability and safety of marine systems.

Contributions of IRT Jules Verne

Within this project, IRT Jules Verne played a central role in developing several key demonstrators. One notable contribution was the re-design and manufacturing of a full-scale (truncated) tidal turbine demonstrator that incorporated a new formulation of 3R Vitrimer resin. This innovative resin enables the recycling, repair, and reshaping of components, paving the way for more sustainable solutions in the marine energy sector.

The demonstrator also included QRS sensors for structural health monitoring (SHM) and a textured anti-fouling coating for drag reduction. Thanks to tests carried out on the multi-actuator test bench at IRT Jules Verne in Angers, the mechanical performance of this new resin was validated. The results were comparable to those of commercial thermosetting resins, confirming the material’s viability for industrial applications.

In parallel, a second demonstrator was developed: a one-third scale tidal turbine blade root. This demonstrator was produced using an innovative One-Shot process, which ensures continuous reinforcement between the skins while significantly reducing production time.

Towards cost and environmental impact reduction

Techno-economic analyses and life cycle assessments of these demonstrators revealed promising results. Depending on the case, the use of 3R resin and automated lay-up or One-Shot processes could reduce production costs by 10-20% and environmental impact by 35-45%. These advancements represent an important step toward more competitive and eco-friendly solutions for the marine energy industry.

A challenging and successful project

“We are proud to have contributed to this particularly challenging project and to have tackled, alongside our partners, the obstacles it presented. The completion of CARBO4POWER is the result of effective collaboration, where everyone was able to bring their expertise in a positive and productive working environment. We would like to thank all the partners for their dedication, hard work, and excellent cooperation throughout the project,” concluded Céline Constantin, Project Manager at IRT Jules Verne.

Thanks to these joint efforts, CARBO4POWER offers a promising future for the integration of innovative technologies in renewable energy, addressing the economic and environmental challenges of tomorrow.

Cet article Final review of the European CARBO4POWER Project: Collaborative innovations for the energy of tomorrow est apparu en premier sur IRT Jules Verne.

The European UPBEAT project, which was launched on 1 May, aims to create new methods and tools for quantifying uncertainties in order to produce safer and more innovative aircraft structures and engines, while reducing uncertainties in cycle times. The project focuses on hybrid metal-composite engine parts which have the advantage of being light, durable and affordable.

The objectives

Improve understanding of the process, structure, properties and performance with a focus on safety.
Advance process models (additive manufacturing & carbon fibre reinforced polymers) for planning and optimisation.
Develop verification and validation using multi-scale models.
Integrate UQ into design, materials, manufacturing, qualification and certification
Demonstrating the technologies developed in UPBEAT using a complex aviation use case.

Budget: €3.9m, including €699.5k for IRT Jules Verne
Duration: 42 months

Partners : PHI-MECA ENGINEERING, SINTEF Manufacturing (NO), SINTEF AS Norway Affiliated (NO), GKN Aerospace Sweden AB (SE), Aerobase Innovations AB (SE) et RISE Research Institutes of Sweden (SE

Cet article IRT Jules Verne wins a new European project: UPBEAT! est apparu en premier sur IRT Jules Verne.

The next steps include the manufacturing of the spars and the assembly, followed by the transfer of all the demonstrators to the IRT’s mechanical test bench in Angers, where trials will be carried out. They will enable the behaviour of the blades to be analysed and validated using various methods, including the Digital Image Correlation synchronized with infrared thermography inspection, and the QRS developed by SENSE in.

The entire consortium is currently meeting in Spain for the M42 meeting at AIMEN Centro Tecnológico, which is in charge of manufacturing the wind blade demonstrators, to review progress ahead of the final phase of the project.

CARBO4POWER is focusing on the development of next-generation wind and tidal turbine blades, using intelligent architectures as well as hybrid and nanotechnology materials.

Cet article European CARBO4POWER project : IRT Jules Verne has just completed the infusion of the two half-blades of the full-scale tidal est apparu en premier sur IRT Jules Verne.

Today, the use of extrusion additive manufacturing is limited to materials whose transformation temperatures and chemical properties render them easy to process. However, their poor mechanical properties limit their fields of application, as well as the complexity and size of the parts produced. The use of technical materials (PAEK, PEI, etc.) for the aeronautical industry remains an open problem.

The project proposes to extend the window of application of additive manufacturing by extrusion of a hot material (wire or granules) to high-performance materials and large, complex parts. It will focus on the development of an out-of-oven process with the creation of a dedicated manufacturing island.

In addition, a prototype digital chain will take account of the materials, machines and physical constraints to guarantee print feasibility while limiting distortion and taking into account the anisotropy of the mechanical and thermal properties of the material.

Cet article Launch of MAXIMA Project est apparu en premier sur IRT Jules Verne.

After 3 years of collaborative development, the European project FIBRE4YARDS proudly announces its results at its closure this week. This collaborative project, dedicated to the use of fiber-reinforced polymers (FRP) in shipbuilding using Industry 4.0 concepts, involves 13 partners from 6 European countries. Focused on optimizing production costs and introducing innovative digital technologies, it marks a major breakthrough for the European naval sector.

Pushing the Boundaries of Shipbuilding with Fiber-Reinforced Polymers

Traditionally used in the construction of lightweight structures for vessels up to 25 meters, FRPs are now making their way onto larger boats, reaching up to 50 meters. However, the full production potential of FRP vessels remains untapped due to prohibitively high production costs. FIBRE4YARDS has addressed this challenge by introducing innovative automated procedures and eliminating semi-artisanal methods, ushering in a new era for the competitiveness of the sector.

The Union of Composite Technology and Naval Excellence

FIBRE4YARDS, aimed at aligning end-user needs with fiber-reinforced plastic (FRP) manufacturing technologies, is propelling shipyard production and maintenance towards promising horizons. The introduction of innovative automated manufacturing methods promises to reduce costs, enhance environmental performance, and optimize European competitiveness. This groundbreaking project has developed digital tools such as digital twins to support the modernization of shipyards by adopting composite manufacturing processes already proven in other sectors such as aerospace and automotive. Major impacts include significant environmental gains, increased manufacturing profitability, and a notable boost to the growth of the European naval sector.

The project’s closure took place in Nantes, hosted by Naval Group and IRT Jules Verne, which housed the 1:1 scale demonstrator of a catamaran structure. 

Read the press release

Cet article The European Project FIBRE4YARDS Redefines the Shipbuilding Industry with Next-Generation Composite Technologies est apparu en premier sur IRT Jules Verne.

Previous projects COSMOS / COSMOS-PEEK were completed in 2022 with the main objective of improving the technological feasibility of the stamping and over-molding processes applied to high-performance materials for the aeronautical industry. The CONNECT project aims at demonstrating the process robustness and at developing a numerical simulation chain to accelerate the certification of aeronautics parts.

Main objectives 

• Define a methodology for the qualification of over-molded interfaces
• Evaluate the repeatability of stamping and over-molding processes (2steps with localized heating)
• Define specific test methods and samples for over-molded interfaces
• Develop specific adhesion laws suitable for the thermal dynamics of the over-molding process
• Develop a predictive cohesive model for the over-molded interfaces behaviour

Cet article The CONNECT project kick-off est apparu en premier sur IRT Jules Verne.

The main objective of this project was to study the feasibility of adapting and implementing a solution for structural health monitoring of a composite offshore wind turbine blade, based on the Digital Image Correlation (DIC) technique.

The mains results are as follows:

– Adaptation of DIC for the detection of defaults, automatic generation of alerts and real-time monitoring of defaults evolutions.

– Coupling of the DIC with a robotic acquisition system

– Transposition and application of DIC to a real & industrial case

Finally, these results provide Siemens Gamesa with solutions and prospects for monitoring structures in order to optimise and reduce maintenance operations costs, by relying on information acquired in real time rather than periodic preventive maintenance.

Furthermore, the elements developed during this project can be applied in other industrial sectors.

Discover the film on the project

Cet article COMPLETION OF RIVERS PROJECT est apparu en premier sur IRT Jules Verne.

The kick-off meeting of this project took place on 9 and 10 May 2022 in O Porriño, Spain, with the presence of representatives of 11 partners from 8 EU Member States (Spain, France, Finland, the Netherlands, Sweden, Austria, Germany and Cyprus). CAELESTIS is being launched for a period of 42 months with a budget of almost 6 million euros.

The objectives of the project are :

• To develop a digital thread across the value chain linking the design, simulation, production engineering and manufacturing of next-generation airframe and engine structures;
• To develop model-based product and manufacturing digital twins, supporting virtual prototyping of next-generation aerostructures by linking and managing design and manufacturing uncertainties;
• To develop advanced HPC-data analytics that supports the design and manufacturing engineering;
• To develop smart manufacturing strategies to identify and reduce in real-time the impact of defects across the manufacturing chain;
• To foster the uptake of the CAELESTIS virtual prototyping ecosystem across the EU aeronautics industry to boost innovation for the future aircraft with a Multi-Actor Approach.

In the framework of CAELESTIS, the Jules Verne Institute is involved in two main work packages:

• The WP 4, which aims to develop 4 digital twins associated with the different steps and processes, necessary for the manufacture of an aerospace part made out of Titanium and Carbon fibre preform and the assembly in environment. Jules Verne is WP4 Leader. Several softwares will be implemented at the scale of each process and then will be digitally linked with each other. The results of these process simulations will be exported to the OGV mechanical performance simulations (WP3). The IRT JV will focus in particular on digital twins for RTM (PAM RTM®) and assembly (MECAmaster®).
• The WP5 aims to quantify and propagate product-process uncertainties in digital workflow. The Jules Verne insitute will focus on the consideration of uncertainties in the stochastic simulation of the RTM process. The result of these simulations will be a stochastic geometry of the part.

The results of the project could lead to lower CO2 emissions from aviation, reduce the costs and risks of designing new aircraft and shorten the time to innovation of tomorrow’s more efficient aircraft.

Coming soon: CAELESTIS will launch its website, as well as the CAELESTIS network, open and accessible to industrial partners and researchers in the relevant fields.

Read the complete press release here

Cet article JULES VERNE INSTITUTE IS INVOLVED IN A NEW EUROPEAN PROJECT: CAELESTIS! est apparu en premier sur IRT Jules Verne.

In the current context, automatic draping technologies are poorly adapted to small parts and require the intervention of specialised operators. While their skills are essential for complex parts, it is interesting to think about automation for simpler parts.  In this way, we can imagine a man/machine pairing that makes it possible to draw the best qualities from each part, i.e. the speed and repeatability of a robot and the dexterity and judgement of an experienced draper.

This 12-month feasibility study identified the technological challenges related to the automation of the draping process, with a focus on the removal and layering tasks, and on prepreg fabric.

An iterative-incremental approach leading to first satisfactory solutions

With an iterative-incremental and highly experimental approach, the work focused on the development and evaluation of gripping and marouflage tools, on the different robotic control strategies for carrying out these tasks and on possible marouflage simulation methods, with the development of a first model.

These results, although conclusive, must be pursued. A follow-up is currently being considered in order to remove the last barriers identified.

Cet article AFAL project completion est apparu en premier sur IRT Jules Verne.