Periodic Reporting for period 2 - INFINITE (Aerospace Composites digitally sensorised from manufacturing to end-of-life)
Período documentado: 2023-12-01 hasta 2025-05-31
INFINITE Project started in June 2022 with the objective of developing ferromagnetic MW-based sensors embedded in composite structural parts and an analyser for continuous monitoring of manufacturing and structural health throughout the component's life cycle. The wireless monitoring system generates digital signals and extensive data, creating a digital twin that captures the structure's history since manufacturing, including maintenance operations.
The project focuses on incorporating advanced sensing technology into aerospace composite components, contributing to transformative digital technologies for the aircraft lifecycle and enhancing competitiveness. The primary goal was to establish a calibrated system that produces valuable data for Structural Health Monitoring (SHM), enabling accurate, cost-effective quality assurance of aerospace composite components. This approach aligns with circular economic strategies, addressing the challenges faced by the European aircraft industry.
To sustain a competitive edge, the incorporation of smart control systems for in-situ monitoring of high-value manufacturing, in-service Maintenance, Repair, and Overhaul (MRO), and End-of-Life (EoL) processes is essential. Digital twins play a crucial role, serving as a digital representation of real assets with intelligent functions to derive maximum benefits, not just as data stores but also as tools for future development.
Composite materials, known for their lightweight and high-performance properties, are extensively used in aircraft manufacturing. The ability to incorporate wireless sensors within the composite structure is critical for digital transformation. This aligns with the development of "intelligent structures," encompassing reader, sensor, and smart material development, contributing to achieving environmental targets in the aircraft industry.
The project focuses on incorporating advanced sensing technology into aerospace composite components, contributing to transformative digital technologies for the aircraft lifecycle and enhancing competitiveness. The primary goal was to establish a calibrated system that produces valuable data for Structural Health Monitoring (SHM), enabling accurate, cost-effective quality assurance of aerospace composite components. This approach aligns with circular economic strategies, addressing the challenges faced by the European aircraft industry.
To sustain a competitive edge, the incorporation of smart control systems for in-situ monitoring of high-value manufacturing, in-service Maintenance, Repair, and Overhaul (MRO), and End-of-Life (EoL) processes is essential. Digital twins play a crucial role, serving as a digital representation of real assets with intelligent functions to derive maximum benefits, not just as data stores but also as tools for future development.
Composite materials, known for their lightweight and high-performance properties, are extensively used in aircraft manufacturing. The ability to incorporate wireless sensors within the composite structure is critical for digital transformation. This aligns with the development of "intelligent structures," encompassing reader, sensor, and smart material development, contributing to achieving environmental targets in the aircraft industry.
During the second reporting period, the project reached a Technology Readiness Level (TRL) of 3–4, marked by several key technical and scientific developments. A portable low-frequency reading system was developed to detect signals from microwires embedded in carbon fibre composites, both on the surface and internally. A wireless sensing system was successfully validated for monitoring changes in microwires during the production of carbon fabrics and composite structures, demonstrating the potential for in-situ monitoring and industrial integration.
A structural health monitoring algorithm was designed to identify and locate defects based on microwire responses to electromagnetic signals. The algorithm was built with flexible pathways to accommodate different data conditions and operational needs. The ability of microwires to detect defects was confirmed during both manufacturing and operational phases, supporting their use in non-destructive evaluation.
Requirements for damage types, environmental factors, and testing procedures were established to guide the systematic validation of sensors. The impact of microwire integration on the mechanical properties of composites was also assessed, ensuring structural integrity is maintained.
A methodology based on diagnostic flowcharts was created to guide repair actions, complemented by a specialized toolkit for maintaining non-crimp fabric structures. An integrated dashboard was developed to support real-time decision-making by maintenance teams, alongside the implementation of material passports to enhance traceability throughout the product lifecycle.
A reuse strategy was defined to enable continued application of sensorized parts in aerospace or transfer to less demanding sectors. Recycling methods were explored for recovering key materials such as pyrolysis oil, microwires, and carbon fibre. The environmental and economic impacts, along with material circularity, were evaluated through Life Cycle Assessment, Life Cycle Costing, and other assessment tools.
A structural health monitoring algorithm was designed to identify and locate defects based on microwire responses to electromagnetic signals. The algorithm was built with flexible pathways to accommodate different data conditions and operational needs. The ability of microwires to detect defects was confirmed during both manufacturing and operational phases, supporting their use in non-destructive evaluation.
Requirements for damage types, environmental factors, and testing procedures were established to guide the systematic validation of sensors. The impact of microwire integration on the mechanical properties of composites was also assessed, ensuring structural integrity is maintained.
A methodology based on diagnostic flowcharts was created to guide repair actions, complemented by a specialized toolkit for maintaining non-crimp fabric structures. An integrated dashboard was developed to support real-time decision-making by maintenance teams, alongside the implementation of material passports to enhance traceability throughout the product lifecycle.
A reuse strategy was defined to enable continued application of sensorized parts in aerospace or transfer to less demanding sectors. Recycling methods were explored for recovering key materials such as pyrolysis oil, microwires, and carbon fibre. The environmental and economic impacts, along with material circularity, were evaluated through Life Cycle Assessment, Life Cycle Costing, and other assessment tools.
Microwire-based sensors were successfully integrated into composite structures without affecting mechanical performance, enabling real-time health monitoring in industries like aerospace, automotive, and wind energy. This can extend service life, lower maintenance costs, and improve safety.
SHM techniques proved effective in detecting defects during manufacturing and service, enhancing quality control and supporting predictive maintenance. A toolkit for sensor-guided repairs was developed to enable condition-based maintenance, reducing unnecessary interventions.
Material passports and dashboards were established to ensure data continuity, supporting traceability, lifecycle management, and digital twin applications. Sustainable end-of-life strategies were identified, offering recycling and reuse pathways for composites and contributing to circular economy goals.
To support adoption, further industrial-scale demonstrations are needed. Engagement with early adopters, business model development, and IPR strategies will aid commercialisation. Standardisation, regulatory support, funding, and international collaboration are essential for market access and global scalability.
SHM techniques proved effective in detecting defects during manufacturing and service, enhancing quality control and supporting predictive maintenance. A toolkit for sensor-guided repairs was developed to enable condition-based maintenance, reducing unnecessary interventions.
Material passports and dashboards were established to ensure data continuity, supporting traceability, lifecycle management, and digital twin applications. Sustainable end-of-life strategies were identified, offering recycling and reuse pathways for composites and contributing to circular economy goals.
To support adoption, further industrial-scale demonstrations are needed. Engagement with early adopters, business model development, and IPR strategies will aid commercialisation. Standardisation, regulatory support, funding, and international collaboration are essential for market access and global scalability.