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.

Breaking barriers in aerostructure certification

The project, titled “Al-based testing pyramid towards virtual certification of next-gen composite aerostructures”, aims to replace the current sequential and labour-intensive aircraft certification pyramid with a digital, interconnected approach. By employing Al and data-driven simulations, pAlramid enables faster de cision-making, reduced physical te sting, and optimised resource use while maintaining stringent safety and performance standards. The project will test its methodologies through four industrial use case s, each addressing critical components of modern aerostructures. These include a vertical stabiliser box fairing and an aircraft door structure, as well as two versions of a wing leading edge, manufactured using advanced thermoplastic and thermoset composites. These demonstrators will showcase the versatility and effectiveness of the virtual testing framework in real-world applications, paving the way for faster market deployment. These demonstrators not only provide proof of concept but also aim to advance technologies in functionalised materials and sustainable manufacturing processes. By the project’s end, these components will achieve Technology Readiness Level (TRL) 4, marking significant progress toward their potential deployment in future aircraft.

A collaborative effort across Europe

Led by IKERLAN S. COOP (Spain), pAlramid brings together a diverse consortium of 13 part ners from seven countries. This multidisciplinary team includes research institutions, industrial manufacturers, and experts in materials, processes, and Al-driven tools, collectively addressing the complexities of modern aerospace challenges. The consortium i ncludes expert s in composite materials and manufacturing proce sses – Institut de Recherche Technologique Jules Verne (France), lnstituto de Ciência e lnovaçao em Engenharia Mecânica e Engenharia lndustrial (Portugal), Fundaci6n GAIKER (Spain), MECA S.A.R.L. (France), and Universitat de Girona (Spain), spe cialist s in digital tools and integration – Brunel University London {United Kingdom) and LKS S. Coop (Spain), and aerostructure manufacturers – Turkish Aerospace (Turkey), POTEZ Aéronautique (France), Koninklijke Fabriek lnventum B.V. (Netherlands), and SOFITEC Aero S.L. (Spain). Finally, Zabala Innovation Brussels (Belgium) leads the disse mination, communication, and exploitation activities, ensuring the project’ s outreach and impact across key stakeholders.

A transformative vision for the aerospace industry

pAlramid aims to accelerate the development and deployment of lightweight, sustainable aerostructures by making the certification process more efficient and reliable. The tools and methods developed in this project will not only reduce costs and timelines but also enable the adoption of advanced materials and processes, setting a new standard for the industry. By addressing the growing need for sustainable and efficient solutions in aviation, pAlramid aligns with Europe’s goals for climate-neutral aviation by 2050. With its innovative approach and strong consortium, the project is poised to make a lasting impact on the aerospace industry and beyond.

Read the press release here

Cet article pAlramid: A new era for composite aerostructures certification takes flight 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.

In figures

• 160 face-to-face and live participants,
• 50 participants in 6 workshops at Centrale Nantes and IRT Jules Verne: sharing, exchanging, practicing and manipulating robots over these two days
• 30 technical and scientific presentations on key robotics topics
• 4 scientific committee members: Zane ZAKE, Brice Renaudeau, Maciej Bednarczyk and Olivier Kermorgant
• 2 key note speakers: Alejandro Hernandez Cordero (Intrinsic) and Vishnuprasad Prachandabhanu (Fraunhofer IPA) and 1 invited speaker: Guillaume Doisy (Dexory)
• 1 networking evening in Halle 6 Ouest, bringing together nearly 100 people for a convivial exchange of ideas.
• 2 technical visits: the M-Lab at Halle 6 Ouest and the robotics technological innovation platform at IRT Jules Verne
• 8 sponsors: Nantes Métropole, the European ACROBA project, Canonical, Dexory, Naval Group, Reebot, 2RM CNRS, Zetta Scale Technology.
• 100% IRT Jules Verne organization team

Back to the program

A taste of ROS with workshops

The workshops, held at Centrale Nantes and IRT Jules Verne, covered concepts such as Gazebo, behavior trees, ROS 2 development environments that can be deployed on robots, and robot programming tests to create a collaborative sorting mini-factory.

Conference at Technocampus Océan

The conference program covered a wide range of topics, with many examples of applications using ROS 2, and exciting talks on the role of ROS 2 in education and industry. Here are just a few examples of the presentations given over the two days at Technocampus Océan:

• Tribulations of a roboticist in impact robotics: the case of agricultural robotics, by Mikael Arguedas – NeoFarm
• ROS 2 at the heart of the railway maintenance robotics ecosystem, presented by Louis-Romain JOLY and Clara Cussaguet – SNCF Group
• Mobile robotics scale-up with ROS 2, by Guillaume Doisy, Dexory
• How can ROS help manufacturers imagine the future of their factories? by Delphine KELLER – NAVAL GROUP, with a focus on the SMARTROBOT project with IRT Jules Verne

Not forgetting the testimonials of our 2 key note speakers:

• Alejandro Hernandez Cordero, Intrinsic, USA, who spoke about the upcoming release of ROS 2 Jazzy and shared the latest information on Gazebo.
• Vishnuprasad Prachandabhanu, Research Associate at Fraunhofer IPA (GER), who presented ROS-Industrial, the community applying ROS to the industrial world, and the projects supported by the European consortium.

Other topics included developer tools presented by ZettaScale Technology and Canonical.

Two R&D robotics and cobotics engineers spoke on behalf of the IRT Jules Verne: Benjamin TREUSSART presented the topic “Automated sensor-based assembly”, and Baptiste VERON gave a presentation on the automated and flexible platform for NDT (CASPR).

Major exposure for our robotics expertise in France

By taking on the organization of ROSCON France, IRT Jules Verne has seized several opportunities:

• Supporting the development of the open-source robotics community in France.
• Position IRT Jules Verne at the forefront of robotics advances in France.
• Develop connections and opportunities to become known as a major player in modern robotics in France.
• Promote the expertise of its team to a public made up of industrials and academics of the sector.
• Promote exchanges and enhance the value of Nantes‘ robotics ecosystem.

Replays

The presentations are online! To see them again or again, go to the ROSCon France 2024 playlist:

Best-of

1 minute to live or relive the best moments of the ROSCON France 2024!

See you in Strasbourg in 2025 for next edition!

Cet article ROSCON France est apparu en premier sur IRT Jules Verne.

The IRT can count on its teams to continue to shine and to consolidate its expertise in the field of composites.

@Nihad SIDDIG, simulation research engineer at IRT Jules Verne, highlighted the MONOCLE project during her presentation “Optimization of the Infusion Process through Numerical Permeability Analysis and Simulation”.

@Yvan Denis, simulation research engineer at IRT Jules Verne, presented the tooling of the DESCARTES project with his presentation “Investigation on factors causing tool distortion in the manufacturing of high-performance thermoplastic composite materials”.

@Matthis Balthazar, PERFORM PhD student, spoke on “Improvement of thermal management of tooling using lattice structures. Application to omega stringer mould”.

@Philippe Le Bot, technical expert in process monitoring, inspection and control at the IRT Jules Verne, presented the MONOCLE project during the “Poster Session” under the heading “Digital shadow dedicated to resin infusion filling process of composite parts” in front of a large and very interested audience.

To round off this special ECCM21 week, the IRT Jules Verne opened its doors for the second time during the week to show visitors around its technology halls. The visit gave industrialists and academics, mainly from Europe, a close-up view of our capacity to develop projects and services in the world of composites. The complementary nature of our teams was particularly highlighted during this comprehensive visit. In all, more than 80 people took part in the tours of our technology halls.

Many thanks to all the participants and speakers for their commitment and contributions!

Cet article ECCM21 It’s over… but what a week for IRT Jules Verne est apparu en premier sur IRT Jules Verne.

The aim of the workshop, held in Brussels, is to maximise the impact and exploit the results of European research in the development and adoption of innovative, efficient, lightweight and sustainable materials and processes. This also contributes to substantial reductions in CO2 emissions, aligning the industry with the EU’s ambition to reach an economy with net-zero greenhouse gas emissions by 2050.

The workshop entitled ‘Efficient, Lightweight, Sustainable Advanced Materials – Supporting EU industries to meet the Green Deal targets’ brought together several research initiatives funded by the European Commission as part of the Horizon Europe program, aimed at tackling these challenges in a holistic way.

The objectives of the workshop were to

– Inform industry stakeholders about the latest advances and research results in this field.

– Facilitate dialogue between the research community and industry to identify industrial needs and future strategies.

– Align research and innovation priorities with forthcoming investments in the EU.

IRT Jules Verne is particularly proud to have had the opportunity to present two of its European projects, FOREST and SUSPENS, at this notable event. These projects illustrate the Institute’s commitment to finding innovative solutions for a more sustainable and competitive industry.

Cet article IRT Jules Verne invited by the European Commission to present two European projects at a workshop on advanced materials 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.

Gathering of excellence: Over 180 participants from Airbus R&T and 11 technocenters specializing in key areas such as additive manufacturing, composite and metallic processes, robotics, and digital co-design and manufacturing contributed to the success of this event. They came from England, Spain, Germany, and, of course, France to animate this European dimension event.

Collaborative dynamics: These two days were marked by captivating conferences, innovative pitches, and fruitful exchanges, creating the conditions for a beautiful collaborative dynamic.

Ingenuity and excellence: Each of the 11 technical centers brilliantly presented their projects and demonstrators, highlighting the ingenuity and excellence that characterize the Airbus community.

Strengthening our commitment: Hosting this event at NAUTILUS reinforces our position in the aerospace industry, marking another significant step in our ongoing commitment alongside our partner Airbus.

Special thanks: A huge thank you to the event sponsors – Andre Bourdais, Frank Hashagen, Mark Bentall, and Olivier Criou – for their support and valuable contribution. Also, a big thank you to the entire Airbus team for the trust placed in us. Finally, a big thank you to the teams at IRT Jules Verne who all contributed to the success of this event!

Opening up to new perspectives: Undoubtedly, this event has opened up new perspectives and strengthened bonds within the Airbus community.

Alongside them, we look forward to contributing to tackling the new challenges that lie ahead.

Cet article AIRBUS is setting up at IRT Jules Verne for 2 days est apparu en premier sur IRT Jules Verne.