The general objective of the RECREATE project is to develop a set of innovative technologies aimed at exploiting the potential of End-of-Life (EoL) complex composite waste as feedstock for profitable reuse of parts and materials in the manufacturing industry. In the light of this, more specific objectives are: - to develop and validate in relevant environment (TRL6) novel reuse strategies for large EoL composite parts based on smart recognition and inspection for sorting (Laser Induced Breakdown Spectroscopy), high precision dismantling (laser-shock) and repair, temperature-assisted reshaping, design for disassembly based on reversible joints, AI-assisted decision support systems; - to develop and validate in relevant environment (TRL6) innovative recycling technologies (catalyst-assisted green solvolysis and electrofragmentation) allowing simultaneous recovery of high quality, integer, clean fibers and of an organic resin fraction reusable as coating material, at the very end of the multiple reuse processes of parts; - to demonstrate at TRL6 the use of smart and green reversible thermoset resins as enabling materials for the realization of the next generation of fiber-reinforced composites with easier repairability and enhanced reusability, facilitating the transition towards recyclable-by-design composites; - to develop digital tools for the quantitative evaluation of the environmental and economic performance of the proposed technologies (LCA/LCC), as well as their circularity assessment and acceleration; - to co-design innovative digital learning resources, based on MOOCs, gamification and digital twins of some specialty technologies developed in the project, with easy adoption and high replicability. The objectives and ambition of RECREATE are fully compliant with the general requirements of the Horizon Europe - Digital, Industry and Space 2021 Work Programme, and with the specific requirements of the call Horizon-CL4-2021-Resilience-01-01.

The SABYDOMA programme addresses developments in the safety by design (SbD) paradigm by examining four industrial case studies in detail where the TRLs will advance from 4 to 6. Each TRL activity will progress from being lab based at TRL4 to being industry based at TRL6. The TRL4 activity will involve only innovation with regular industrial communication whereas the TRL6 activity will involve industrially located activities with innovation communication. One of the novel themes of this study is to use system control and optimisation theory including the Model Predictive Control (MPC) philosophy to bind the whole subject of SbD from laboratory innovation to the industrial production line and from decision making processes to project governance. An equally important innovative step is the building of high throughput online platforms where nanomaterial (NM) is manufactured and screened at the point of production. The screening signal controls the NM redesign and production in a feedback loop. Screens will involve (a) physiochemical sensing elements (b) in-vitro targets of increasing complexity from the 2D biomembrane to cell-line and more complex cell-line elements; and, (c) multiple in-vitro targets with multiple end-points; developed in current H2020 projects. Two of the industrial studies include composite coating manufacture where the coating’s stability and toxicity will be tested using a flow through microfluidic flow cell system coupled to online screens. This is part of the release and ageing investigations on the NM and NM coatings and the results of these will feed back to the production line design. At every step on the TRL ladder the in-silico modelling will be applied to optimise and redefine the relevant activities. By the same token regulatory and governance principles of SbD will be used to refine the technological development. The final deliverable will be four distinct technologies applying SbD to the four industrial processes respectively.

The CUSTOMISIZE project aims to develop a new family of carbon fibres’ sizing in order to improve the interfacial adhesion between recycled carbon fibre (rCF) and polymers (thermoset and thermoplastics) and cementitious matrices. The goal of this is to improve the strength, toughness and environmental stability of the composites prepared with the resized fibre. The specific sizing will be developed for non woven mat and chopped tow of recycled carbon fibres. The new upgraded recycled carbon fibre will be used to produce new composites with cementitious or polymeric matrices (thermoset and thermoplastic). The proposed strategy is the development of specific sizings for different polymeric and cementitious matrices through the incorporation of coupling agents along with the sizing materials, which through different mechanisms (covalent bond, hydrogen bond, Van der Waals interactions...) will create active points at the CF surface. Those will be responsible for chemical interactions with the matrix. New approaches as the use of Polyhedral Oligomeric Silesquioxanes (POSS), which consist of a rigid organic cubic silica-oxygen core surrounded by eight organic groups, will be used. CUSTOMISIZE also proposes to validate Steam Water Thermolysis, a current method to recycle CF, in the process to introduce chemical functionalities on the fibers that will be able to interact with the sizing. In addition, plasma viability will be studied due to its capability to create new chemical functionalities on fibers and also, the advantages that has compared to industrial electrochemical processes. It is expected to increase the interfacial shear strengths (IFSS) between rCF and the different matrices by up to 90%. A detailed Life Cycle Assessment (LCA) of the materials and processes will be carried out. These data will be used to assess the impact of the new sizing and its incorporation into different materials, and to support the success of the new developments in terms of sustainabil

CUSTOM-ART aims at developing the next generation of building and product integrated photovoltaic modules (BIPV and PIVP respectively), based on earth-abundant and fully sustainable thin film technologies. Nowadays, BIPV and PIPV are identified as key enabling technologies to make “near Zero Energy Buildings” and “net Zero Energy Districts” more realistic, through the integration of a new generation of photovoltaic modules capable of entirely replacing architectural/mobility/urban-furniture passive elements. This promising scenario of mass realisation of BIPV and PIPV solutions can only be achieved by developing cost-efficient and sustainable thin film technologies with unbeatable aesthetic functionalities, including mechanical flexibility and optical tuneability. Unfortunately, mature materials already available at the market such as Cu(In,Ga)Se2 or CdTe are formed by scarce and expensive elements (In, Ga and Te), or toxic ones (Cd). Considering this, CUSTOM-ART will join for the first time a leading group of companies and academic partners all around Europe, to develop advanced BIPV and PIPV products (flexible and semi-transparent solar modules), based on earth abundant kesterite materials, which have been demonstrated in two previous European projects to be at the forefront of emerging inorganic thin film technologies. By combining advanced strategies for materials properties management, with customized modules design in a circular economy approach, two types of products will be developed including flexible PV modules (polymer and steel supports) and semi-transparent (polymer). CUSTOM-ART will bring these technologies from TRL4-5 up to TRL7, demonstrating very competitive conversion efficiencies (20% at cell and 16% at module level) and durability (over 35 years), at a reduced production cost (< 75 €/m2), using exclusively abundant elements and contributing to ensure the full sustainability and competitiveness of the European BIPV and PIPV Industry.

The Large Passenger Aircraft (LPA) Platform 2 – Multifunctional Fuselage Demonstrator (MFFD) will employ new combinations of airframe structures, cabin/cargo, and system elements using advanced materials, notably HPTP composites. The MFFD is focused on achieving significant cost and weight reductions, coupled with high production rates. To bring these materials to market, there is a need to validate direct joining methods, which eschew traditional adhesive bonding in order to reduce cycle time and improve joint quality. The MECATESTERS project represents a key step in the progression of such technologies to widespread use in the aerospace sector. It will permit a greater level of understanding of the micro-mechanical behavior of the interfaces – an understanding which is currently limited: issues such as aging, healing, processing parameters, and durability need to be investigated in greater detail in order to develop a coherent approach. The MECATESTERS project will elucidate many aspects of thermoplastic joining using precision thermoplastic welding (PTW) methods. It will examine systematically the effects of surface condition, matrix aging, and bonding method on the reliability and performance of assemblies bonded using a variety of thermoplastic welding technologies.