Periodic Reporting for period 1 - VITAL (InnoVatIve processing Technologies for bio-based foAmed thermopLastics)
Période du rapport: 2022-06-01 au 2023-11-30
Biobased thermoplastics made from renewable resources present a more sustainable alternative to fossil-based plastics. However, widespread adoption of biobased thermoplastics as a replacement for fossil-based thermoplastics is held back by:
i) processability challenges; ii) inadequate longevity and performance; and iii) recyclability challenges.
VITAL (InnoVatIve processing Technologies for bio-based foAmed thermopLstics) brings together a pan-European consortium of leading RTOs, innovative SMEs and industrial manufacturers to address these challenges by developing innovative thermoplastic processing solutions for foamed thermoplastics, based on three biobased thermoplastic processing value chains:
1. Novel 3D printing processes based on granulated feedstocks for mould-free, additive manufacture for rapid prototyping and bespoke production and massively reduce lead time and costs.
2. Bead foaming processes combined with radio-frequency (steam-free) heating.
3. Foam Injection Moulding (FIM) with AI-based process control of instrumented equipment allowing for tight control of critical parameters such as temperature, speed and residence times to ensure part conformity.
In addition to process innovation, VITAL will develop new biobased thermoplastic blends that are optimised for high strength and flame retardance, whilst enabling high rates of recyclability. The materials and processes developed in VITAL will be demonstrated across multiple applications through the production of bio-based thermoplastic parts for white goods, automobiles, and ship interiors.
The overarching project ambitions are focused on overcoming the key challenges that have been recognised as major roadblocks to the broad adoption of bio-based materials. VITAL will look at multiple manufacturing processes ranging from high-volume injection moulding (conventional and foamed) and low to medium volume 3D printing. The project will build the required knowledge around process performance, process parameters and crucially, bio-based material performance. An open database of bio-based material properties and performance during foaming will be built to speed-up industry adoption. Circular by design business models, sustainability and reduced environmental footprint will be achieved across three different manufacturing processes and value chains using digitally optimised recycling processes, recycling additives packages and optimised formulations.
The current skills gap will be addressed by creating a ‘Learning Factory’ including a vocational training programme to ensure up-skilling of the workforce and thus maximum adoption and impact of the project outputs. Finally, demonstration parts will be manufactured and evaluated for seven different case studies covering white goods, automotive and marine sectors.
VITAL will contribute towards a number of EU initiatives particularly in economic, green and manufacturing growth:
• 2020 Circular Economy Action Plan which has the aim of making sustainable products the norm in the EU.
• Made in Europe, co programmed European Partnership, related to EU policies addressing manufacturing, the new industrial strategy for Europe, the European Green Deal and a Europe fit for the digital age.
The project also addresses the three core objectives of the European Growth Model which are based on moving towards a resilient, green and digital economy. These will bring multiple benefits to the EU across the environment, health, security of supply and economy. VITAL is built upon a foundation of globally strong and growing markets. The foamed polymer product market sector in particular is a critical part of global economy and is predicted to expand from €123B in 2021 at a compound annual growth rate (CAGR) of 3.6% to 2030. Replacement of fossil-based materials with bio-based alternatives also has the potential to offset ~57,000 tonnes CO2 eq/annum.
VITAL consortium consisting of industrial processors and equipment manufacturers along with end-user partners from the automotive, electronics and marine sectors and leading research and technologies organisations from across Europe. The partnership is led by Finnish research institution VTT and consists of 14 organisations in total – Avient Corporation (Germany)*, Brinter (Finland), Arcelik (Turkey), Centro Research Fiat, Stellantis (Italy), Meyer Werft (Germany), Farplas (Turkey), Tofas (Turkey), Fraunhofer (Germany), PIEP (Portugal), Idener (Spain), Meyer Turku (Finland), Floreon (UK) and Iconiq Innovation (UK). *Global Headquarters Cleveland, Ohio
i) processability challenges; ii) inadequate longevity and performance; and iii) recyclability challenges.
VITAL (InnoVatIve processing Technologies for bio-based foAmed thermopLstics) brings together a pan-European consortium of leading RTOs, innovative SMEs and industrial manufacturers to address these challenges by developing innovative thermoplastic processing solutions for foamed thermoplastics, based on three biobased thermoplastic processing value chains:
1. Novel 3D printing processes based on granulated feedstocks for mould-free, additive manufacture for rapid prototyping and bespoke production and massively reduce lead time and costs.
2. Bead foaming processes combined with radio-frequency (steam-free) heating.
3. Foam Injection Moulding (FIM) with AI-based process control of instrumented equipment allowing for tight control of critical parameters such as temperature, speed and residence times to ensure part conformity.
In addition to process innovation, VITAL will develop new biobased thermoplastic blends that are optimised for high strength and flame retardance, whilst enabling high rates of recyclability. The materials and processes developed in VITAL will be demonstrated across multiple applications through the production of bio-based thermoplastic parts for white goods, automobiles, and ship interiors.
The overarching project ambitions are focused on overcoming the key challenges that have been recognised as major roadblocks to the broad adoption of bio-based materials. VITAL will look at multiple manufacturing processes ranging from high-volume injection moulding (conventional and foamed) and low to medium volume 3D printing. The project will build the required knowledge around process performance, process parameters and crucially, bio-based material performance. An open database of bio-based material properties and performance during foaming will be built to speed-up industry adoption. Circular by design business models, sustainability and reduced environmental footprint will be achieved across three different manufacturing processes and value chains using digitally optimised recycling processes, recycling additives packages and optimised formulations.
The current skills gap will be addressed by creating a ‘Learning Factory’ including a vocational training programme to ensure up-skilling of the workforce and thus maximum adoption and impact of the project outputs. Finally, demonstration parts will be manufactured and evaluated for seven different case studies covering white goods, automotive and marine sectors.
VITAL will contribute towards a number of EU initiatives particularly in economic, green and manufacturing growth:
• 2020 Circular Economy Action Plan which has the aim of making sustainable products the norm in the EU.
• Made in Europe, co programmed European Partnership, related to EU policies addressing manufacturing, the new industrial strategy for Europe, the European Green Deal and a Europe fit for the digital age.
The project also addresses the three core objectives of the European Growth Model which are based on moving towards a resilient, green and digital economy. These will bring multiple benefits to the EU across the environment, health, security of supply and economy. VITAL is built upon a foundation of globally strong and growing markets. The foamed polymer product market sector in particular is a critical part of global economy and is predicted to expand from €123B in 2021 at a compound annual growth rate (CAGR) of 3.6% to 2030. Replacement of fossil-based materials with bio-based alternatives also has the potential to offset ~57,000 tonnes CO2 eq/annum.
VITAL consortium consisting of industrial processors and equipment manufacturers along with end-user partners from the automotive, electronics and marine sectors and leading research and technologies organisations from across Europe. The partnership is led by Finnish research institution VTT and consists of 14 organisations in total – Avient Corporation (Germany)*, Brinter (Finland), Arcelik (Turkey), Centro Research Fiat, Stellantis (Italy), Meyer Werft (Germany), Farplas (Turkey), Tofas (Turkey), Fraunhofer (Germany), PIEP (Portugal), Idener (Spain), Meyer Turku (Finland), Floreon (UK) and Iconiq Innovation (UK). *Global Headquarters Cleveland, Ohio
VITAL’s first 18 months has gone roughly to plan, yielding many interesting and important results on which to build in the coming years. A brief outline of the headline developments follows:
- Value Chain 1: 3D Foam Printing. The design and assembly of a new 3D foam printing head has been completed. The incorporation into the printer test platform is ongoing. Two simulation models have been built: i) A 3D foam extrusion model using computational fluid dynamics; and ii) an extrusion model based on heat exchanger to enable control of gas concentrations.
- Value Chain 2: Bead Foaming and bead foam processing. A range of biobased polymers and additive formulations for generic structures and end-user applications were selected for testing. Early trials in bead foam process optimisation and bead foam moulding process optimisation began, producing foams with good fusing behaviour.
- Value Chain 3: Injection moulding and foam moulding. The most promising samples for foam injection moulding were selected and injection for characterization was undertaken. Stage 1 and 2 testing of these samples is complete.. Results will feedback to optimisation activities to improve the foam injection moulding process.
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- Value Chain 1: 3D Foam Printing. The design and assembly of a new 3D foam printing head has been completed. The incorporation into the printer test platform is ongoing. Two simulation models have been built: i) A 3D foam extrusion model using computational fluid dynamics; and ii) an extrusion model based on heat exchanger to enable control of gas concentrations.
- Value Chain 2: Bead Foaming and bead foam processing. A range of biobased polymers and additive formulations for generic structures and end-user applications were selected for testing. Early trials in bead foam process optimisation and bead foam moulding process optimisation began, producing foams with good fusing behaviour.
- Value Chain 3: Injection moulding and foam moulding. The most promising samples for foam injection moulding were selected and injection for characterization was undertaken. Stage 1 and 2 testing of these samples is complete.. Results will feedback to optimisation activities to improve the foam injection moulding process.
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The work package WP5 Demonstration of use cases starts at M19 and the real use cases will show the applicability of the developed materials and processes.