Buildings wield substantial influence on the environment, accounting for a hefty 30% of global energy usage and a consequential 19% of greenhouse gas emissions. To combat this looming crisis, the Net-Zero Energy Building (NZEB) concept emerges as a transformative paradigm shift in the world of construction. In the midst of this environmental renaissance, a digital revolution sweeps across manufacturing, presenting a tantalizing prospect of reducing embodied CO2 and enhancing thermal control. Yet, a considerable chasm separates these cutting-edge digital technologies from structures crafted from sustainable materials. The intricacies of computational and algorithmic design struggle to encapsulate the rich tapestry of Nature multi-scale marvels, the very essence of this green metamorphosis. Bridging this gap could boost digital fabrication to a mass production system, but issues include the complexity of multi-scale modeling, reliability uncertainties, technical limitations in 3D printing, and poor solution versatility. PANTAREI project addresses all these challenges by implementing a revolutionary adaptive intelligent computational irreversible thermodynamics paradigm to design and assess novel bio-waste-derived meta-structures for the reduction of embodied CO2 in buildings. PANTAREI over-arching aim is to extend the capabilities of current computational tools for material design, by developing adaptive solutions based on the intertwining of virtual physics of failure and non-equilibrium thermodynamics principles for the bio-waste multi-scale meta-structure design and tailored realization through the entire structure life-cycle with a human-centered perspective. This could be materialised only with the aid of a multi-disciplinary stakeholder coalition, which involves renowned universities and companies, leaders in computational/digital design of multi-scale meta-structures and sustainable manufacturing.

Biologicalisation considers the convergence of biology, engineering, and information technologies and offers the prospect of dramatic step-change scenarios for innovative development in many different manufacturing applications. ORGANIC will enable the biological transformation of Additive Manufacturing (AM) processes integrating bio-inspiration from nature (complex-lattice structures), bio-intelligent technologies and architectures (cognitive and evolutionary capabilities), and biomaterials (fully recyclable biocomposites) into Fused Granulate Fabrication (FGF) additive manufacturing technology. Project’s biointelligent architecture consists of: 1) Integrated process-structure-property-performance (PSPP) open optimisation tool; 2) High-precision and digitized FGF equipment; and 3) A novel cognitive control system with self-X capabilities (self-configuration, sel-monitoring, self-optimization and self-healing) for real-time data-driven decision-making that will provide autonomy to the printing process. On top the AI-based gentelligence system enables the long-term AM process evolution as an organism that evolve from generation to generation, thus allowing continuous improvement of the AM process (including hardware and software) and future printed products (lifelong learning), so reliability and sustainability of the production process are guaranteed. ORGANIC technologies will be validated in one manufacturing value chain (wind energy sector) through the first-time-right fabrication of large highly optimized bioinspired products (spar cap or shear web components used on large offshore blades) made of the combination of different fully-recyclable fiber-reinforced biocomposites using FGF additive manufacturing techniques, starting at TRL4 and achieving TRL6 by the end of the project.

To ensure global competitiveness of small and medium European shipyards, a step change is needed. The key to accomplish this relies on overcoming high production costs and low repeatable quality processes which currently inhibit mass production of Fibre Reinforced Plastic (FRP) ship parts. FIBRE4YARDS will bring a cost-efficient, digitized, automated and modular FRP vessel production approach to increase EU shipbuilders’ competitiveness. FIBRE4YARDS’ objective is to match end-users’ needs with targeted advanced production technologies (adaptive molds, ATP/AFP, 3D printing, curved pultrusion profiles, hot stamping, innovative composite connections) from other competitive industrial sectors, and to transfer, adapt and combine them to improve FRP shipyards’ production and maintenance, in a Shipyard 4.0 environment. Real-scale demonstrators will be designed and manufactured to prove feasibility of technologies. Based on the targeted technologies, design and engineering of small/medium-length FRP vessels will be assessed using advanced computational tools. Compliance with the regulatory framework will be ensured, and the necessary personnel training will be provided. All within validated and viable business models targeting a circular and resource efficient maritime sector. This will lead to an improved cost effectiveness of European shipyards and their supply chain, an increased turn-over and a growth of jobs with new 21st century skillsets. Consortium’s high number of SMEs and a FRP shipyard, facilitate direct exploitation in the targeted supply chain. A robust cost-benefit analysis for stakeholders, business plans for successful commercialization and market uptake will be provided, specifically recommending an adequate IPR protection strategy. Environmental impact diminution is achieved through weight reduction (less fuel consumption), recyclable materials, energy efficient production and addressing noise pollution. The 36 months project requests 5 941 720 € funding.