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We are excited to share with you the fourth newsletter of the r-LightBioCom project, which proposes a paradigm
shift in the way high-performance composites (HPC) are manufactured and
recycled, unlocking sustainable-by-design production of lightweight HPC.
In this issue, you will be able to find out about three project milestones we have reached recently:
- Innovative Recycling Technologies: Successful recycling of aramid fibres using supercritical fluids, processed into yarns for tunnel lining
- Sustainable Composite Manufacturing:
a) Resin transfer moulding (RTM) with frontal photopolymerisation
b) Novel microwave curing process
- Advanced optimisation tools: The
Coupled Ecological Optimisation (CEO) tool, a multi-objective
optimisation framework for balancing ecological, economic, and
structural factors in bio-based composites
Additionally, we share updates on our collaborations and more. Enjoy reading!
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Three Project Milestones achieved |
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r-
LightBioCom aims at developing bio-based, high-performance composite
materials, alongside sustainable manufacturing and recycling methods, as
well as advanced optimisation tools. In December 2024, the project
reached three important project milestones: |
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Advancing Composite Recycling
through Innovative Recycling Methods |
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In r-LightBioCom, project partners FeyeCon, FECSA, AITEX, Hochschule Kaiserslautern (University for applied Sciences), and Leibniz-Institut für Verbundwerkstoffe are exploring innovative recycling technologies, including those based on supercritical fluids, to separate valuable reinforcement fibres from their resins. This approach aims to generate new raw materials, promoting a more sustainable, circular economy.
One
project milestone in advancing composite recycling has been reached
with the successful preparation of recycled fibres for the implementaion
in the project's construction use case. As part of this, innovative
recycling methods have been applied to ballistic helmets made from
thermoset composites with aramid fibres and phenolic resin. One major
achievement was the use of supercritical carbon dioxide (Sc-CO₂)
co-solvent recycling, which allowed for the removal of 90% of the resin
while retaining 90% of the fibres’ original strength. The recycled
fibres were then processed into yarns, which will be used in tunnel
lining applications within the r-LightBioCom infrastructure use
case. This success highlights the potential of using recycled
materials in practical, high-performance applications.
Read more about this achievement here: Using Sc-CO2 Co-Solvent Recycling, r-LightBioCom successfully recycles Thermoset Composites into high-performance Yarns
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Novel Fast-Curing Technologies for Composites |
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Schematic illustration of novel resin transfer moulding (RTM) mould with UV curing technology
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Project partner CIDAUT
is developing innovative, fast-curing technologies in r-LightBioCom
that use bio-based materials to improve composite manufacturing
efficiency while reducing environmental impact.
CIDAUT has developed an innovative resin transfer moulding (RTM) mould with frontal photopolymerisation of bio-based resin systems, incorporating a vacuum infusion system assisted by microwaves.
This setup significantly reduces energy consumption and processing time
compared to traditional autoclave curing, while maintaining the
mechanical properties of the composites. Additionally, the use of
bio-resins and natural fibres helps meet the growing demand for
sustainable materials.
Additionally, CIDAUT developed a novel microwave curing process,
which offers a more efficient and sustainable alternative to
traditional curing processes. By utilizing microwave energy to heat the
resin, this newly developed microwave curing process addresses the
challenge of poor thermal conductivity in polymers, while ensuring high
mechanical strength, durability, and lightweight properties, which is
essential for high-performance composites.
Read more on these developments here: r-LightBioCom reaches Milestone on the Development of innovative fast-curing Technologies for Composites
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Advanced Optimisation Tools for Composites |
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Project partner Coventry University has successfully developed the Alpha version of the Coupled Ecological Optimisation (CEO) tool,
an innovative multi-objective optimisation framework that integrates
and balances ecological, economic, and structural parameters to optimise
bio-based composite material products.
The CEO tool has the
potential to significantly reduce product design times and minimise the
need for extensive mechanical testing, allowing for lower costs and
faster implementation of new designs. Moreover, through consideration of
mechanical properties, performance, sustainability and recyclability of
the materials and products, it can help industries make smarter,
greener, and more cost-effective composite material choices.
Read more on the CEO here: r-LightBioCom reaches Milestone in innovative Multi-objective Optimisation for sustainable Composites
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In collaboration with five other Horizon Europe research projects, we have recently launched the EcoComposites Cluster
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The EcoComposites Cluster is a communication and dissemination cluster that brings together six research projects funded under the Horizon Europe framework. Its goal is to increase the reach and impact of
the more sustainable composite solutions being researched and developed
by the projects involved in the cluster, promoting their visibility,
acceptance, and adoption.
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The Cluster's Research Projects:
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The
cluster’s projects focus on the research and development of sustainable
composite solutions that minimize the environmental impact of composite
materials throughout their entire lifecycle, from production to use,
disposal, and beyond through effective recycling measures. Key
objectives include reducing emissions and energy consumption, developing
efficient recycling methods, and promoting circular value chains to
reduce waste and dependency on non-renewable resources. Through
increasing the reach and impact, cluster
aims to facilitate the wider application of sustainable composite
materials across various industries, contributing to a
resource-efficient and climate-neutral future in line with the goals of
the EU Green Deal.
Learn more about the EcoComposites Cluster in our:
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The
EcoComposites Cluster has been established in the context of the
Horizon Results Booster services delivered to r-LightBioCom (GA N.
101091691), FOREST (GA N. 101091790), FURHY (GA N. 101091828), MC4 (GA
N. 101057394), SUSPENS (GA N. 101091906), REPOXYBLE (GA N. 101091891).
This product does not reflect the views of the European Commission.
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4th r-LightBioCom Project Meeting |
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On
6th and 7th November 2024, the r-LightBioCom project held its 4th
project meeting in the Netherlands. During the event hosted by FeyeCon, all project partners came together to present and discuss the project's progress and achievements. Additionally, attendees had the opportunity to visit FeyeCon's R&D facilities, and had the chance to view, handle, and discuss the various samples produced over the past months.
Key achievements in the field of sustainable fibres:
- Production of nonwovens
and composite materials using an innovative polypropylene (PP) and
polyamide (PA) matrix, with mechanical properties rigorously evaluated
to characterize reinforcement fibers for various applications.
- Achievement of a major
milestone with 30% replacement of standard PP by recycled polypropylene
(rPP), enhancing sustainability without compromising performance.
Key achievements in the field of fast curing technologies:
- Design and manufacture
of the final RTM mould for photopolymerization curing, with the process
optimised using bio-based commercial resins reinforced with flax, glass,
carbon, or basalt fibers.
- Successful optimisation
of elements for vacuum infusion with microwave curing, and completion of
testing for bio-based reinforced resins.
Key achievements in the field of innovative recycling methods:
- Success in recycling
ballistic helmets via Sc-CO2 co-solvent recycling, with recycled aramid
fibers proving suitable for new yarn production.
- Effective use of phenolic resin recyclates in the production of foams.
Key achievements in the field of Life Cycle Assessment (LCA):
- Advanced modeling of resins and fibers, providing a deeper understanding of project-relevant materials.
- Development of new recycling models that provide benchmarks for comparative Life Cycle Assessment.
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Inspiring the Next Generation of Innovators |
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Experimentation days at MI(N)Tmachwelt 2024
05.-07.09.2024
Project partner Leibniz-Institut für Verbundwerkstoffe (IVW) participated in the experimentation days at MI(N)Tmachwelt 2024 at the Gartenschau Kaiserslautern. At IVW's
stand, children had the opportunity to explore various composite
materials and experience their properties firsthand. It was three
exciting days full of joy, discoveries, and teamwork.
Read more about the event under: IVW at experimentation days at MI(N)Tmachwelt 2024
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r-LightBioCom in #ED10: Ecosistema Innovador I+D+I |
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#ED10: Ecosistema Innovador I+D+I
23.10.2024
Project coordinator AITEX participated at the #ED10: Ecosistema
Innovador I+D+I. At the event, streamed live on YouTube, experts from
the sector shared their knowledge on business digitisation, the latest
technological tools and success stories in the implementation of
research, development and innovation in various industries.
AITEX
offered valuable insights into the sustainability challenges facing
European industries, with a specific focus on textiles becoming more
environmentally friendly, which also involves recovering materials,
enhancing product value, and designing for durability. As another prime
example of this at the European level, AITEX
introduced r-LightBioCom, which was presented as a decisive step
towards the integration of sustainable raw materials with a focus on
ecological and recycled resources.
Read more on the interview on our website: Driving Sustainable Innovation in European Industries – Insights from #ED10 Ecosistema Innovador I+D+I
Watch the video (in Spanish) here: #ED10: ECOSISTEMA INNOVADOR I+D+I
(Screenshots taken from the YouTube video.)
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24.-26.09.2024AITEX
presented research work on sustainable composites and revalorization of
reinforcing fibers within the framework of r-LightBioCom, sharing
insights into adapting technologies such as blending, carding and
spinning for processing recycled carbon fiber and other fiber yarns
through a poster presentation. View the poster here: Poster |
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3rd Conference on Advanced Materials
12.-14.11.2024CIDAUT showcased its research on novel manufacturing methods, namely frontal photopolymerization with UV, developed in r-LightBioCom. |
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4th International Conference 'Circular Economy for Textiles & Plastics' 19.-20.11.2024
AITEX
represented r-LightBioCom showcasing the project’s innovation
strategies and expected outcomes for the sustainable high-performance
composites that will be developed in the project through a poster
presentation.
View the poster here: Poster |
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Aachen Dresden Denkendorf International Textile Conference
21.-22.11.2024
Hochschule Kaiserslautern
(University for applied Sciences) presented their research on natural
fibre reinforced polymer composites, which presented their research on
natural fibre reinforced polymer composites.
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Estudio y simulación del proceso de fotopolimerización inducida catiónica en materiales compuestos termoestables
(Study and simulation of cationic induced photopolymerisation process in thermoset composites)
P. Contreras (1), L. Matesanz (1), M. Santiago (1), M. Fernández (1), E. Cañibano (1, 2)
(1) Fundación CIDAUT, Pl. Vicente Aleixandre Campos, 2, 47151 Boecillo, Valladolid.
(2) Universidad de Valladolid, Paseo del Cauce 59, 47011 Valladolid, España
In: RevistaPlásticosModernos (RPM); No. 804, October 2024, 11-16.
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Autoclave
processes have been traditionally used effectively in the production of
thermoset composites, although in recent years, out-of-autoclave (OOA)
approaches have become increasingly important. The OOA techniques reduce
curing times and generate high energy efficiency, leading to energy
savings and a reduction in greenhouse gas emissions. Technologies that
directly heat the sample, known as fast curing, stand out. In this
framework, CIDAUT
proposed the use of an efficient and more sustainable processing
technique, called resin transfer molding (RTM) together with frontal
photopolymerization.
In the present
study, photopolymerization has enabled the rapid curing of polymer
composites by RTM, resembling a serial industrial process that provides
composite materials with properties similar to those obtained by
traditional thermal curing.
For more information, visit: Revista Plásticos Modernos
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Follow us on social media, and share the information with your colleagues and friends.
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Contact: info@r-LightBioCom.eu
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Funded
by the European Union under Grant Agreement Project No 101091691. Views
and opinions expressed are however those of the author(s) only and do
not necessarily reflect those of the European Union. The European Union
cannot be held responsible.
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Copyright © 2023 r-LightBioCom, All rights reserved.
Imprint
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