DOMMINIO aims at developing an innovative data-driven methodology to design, manufacture, maintain and pre-certify multifunctional and intelligent airframe parts (composed of high-quality in-situ consolidated composite laminates and high-performance 3D-printed reinforcement elements) through a cost-effective, flexible and multi-stage manufacturing system based on the combination of robotized ATL and FFF technologies, supported by advanced simulation tools, on-line process & quality monitoring, SHM systems-enabled by embedded novel CNT-based fibre sensors and data analytics. Innovative multifunctional thermoplastic filaments will be employed to incorporate novel continuous CNT fibre-based piezoresistive strain sensors in the laminate, to enable reversible joining (using magnetic NPs) and increase the structural integrity (using continuous CF) of the 3D-printed reinforcements. Flexible automation of ATL and FFF manufacturing processes will be enabled by the development of new laser-scanning and smart nozzle systems, the simulation of ATL plies consolidation and interlaminar delamination in FFF and the development of novel air-coupled ultrasound quality monitoring systems. Besides, advanced modelling will support the selection of right process window parameters and the optimal production planning strategy, ensuring the quality of the final component. In addition, physics- and data-driven models (Digital Twin) will provide real-time data-driven fault detection capabilities supporting the implementation of new methodologies for SHM&M of multifunctional airframe parts. The DOMMINIO multi-stage manufacturing systems and digital pipeline will be tested and validated at lab-scale in two representative airframe parts (a multifunctional access door panel and a leading-edge wing prototype), enabling the realization of the DOMMINIO solutions in a laboratory environment, in order to assess novel MDO and MRO methodologies, their life analysis and virtual certification potential.

In order to meet the objectives of the European Green Deal by 2050 in the aviation sector, the transition towards H2-powered aviation is the solution with the most potential. Although hydrogen-powered aircrafts exist, the current cost of storing and using H2 as a fuel in prolonged flights make their democratization impossible. The main blocking point is the absence of viable storage systems of H2 in aircrafts considering the strict limitations in terms of weight, volume, and cost-efficiency. A sensitivity analysis shows how the economics depend on the tank’s gravimetric index (GI). Today’s technology can barely achieve 20% GI for 500kg of H2, while industry actors need at the very least 35% GI for 500kg of H2 to transition towards H2-powered aviation. OVERLEAF intends to develop a game changer Liquid Hydrogen (LH2) storage tank to enable the transition towards H2-powered aviation. Based on a disruptive design (under patent process) and leveraging innovative materials and technologies, the OVERLEAF solution is expected to boast a GI higher than 60% for 500kg of LH2, with no venting over 24h. Furthermore, the concept is an enabler for using the aircraft’s fuselage as the outer tank, allowing to seamlessly integrate the tank in the aircrafts structure. OVERLEAF will have an interdisciplinary R&D approach focusing on advance materials engineering, testing and combination at lab and at pilot scale, together with appropriate simulation of different design architectures of the hydrogen storage system. The project will be based on three distinctive phases and implemented in 7 Work Packages. The consortium includes multidisciplinary partners from 6 different EU countries and contains all the necessary expertise and know-how to carry-out all tasks needed to achieve OVERLEAF’s ambitious objective.

To enable a technologically and economically feasible H2-powered aviation, new integral LH2 tank solutions are required that could serve as part of the airframe main structure and capable of withstanding its respective loads. The H2ELIOS project will develop an innovative and effective lightweight LH2 storage system for aircraft. It will be implemented as demonstrators in two fuselage-like cylinder section with approximately 1.9 m of external diameter and approximately 2.3 m of external length. These demonstrators would be duly supported by component and subsystem ground tests at appropriate scale at project completion (TRL 5 at storage level). The aim is that the concept is ready to be embedded and integrated in a specified aircraft architecture for flight demonstration in later stages. H2ELIOS will provide a feasible and novel low-pressure double-layer composite tank-based system, enabling the tank shape to be either conformal or non-conformal to the profile of the aircraft. Its general effectiveness will be assessed in terms of high GI performance and easiness of integration within the aircraft structure. This concept will be supported by latest evolutions of innovative methods and technologies in terms of multidisciplinary design development, manufacturing processes and means of compliance and shall be demonstrated in operational conditions: first on ground up to TRL5 and then in flight by the end of Clean Aviation Phase 2 clearing a TRL6 maturation gate. Finally, delivery to the market is expected in the 2030-2035 period. In this way this project shall contribute to accomplish the objectives of the European Green Deal regarding decarbonization of the aviation industry. The activities of H2ELIOS will be supported by explicit agreed support of EASA and an External Advisory Board comprising commercial aircraft OEMs, H2 management and cryogenics experts, MRO services, airlines, aircraft system integrators, materials developers and suppliers and airports operation

The European robotics industry is moving towards a new generation of robots, based on safety in the workplace and the ability to work alongside humans. This new generation is paramount to making the factories of the future more cost-effective and restoring the competitiveness of the European manufacturing industry. However, the European manufacturing industry is facing the following challenges: (1) lack of adaptability, (2) lack of flexibility, and (3) lack of vertical integration. The proposed SYMBIO-TIC project addresses these important issues towards a safe, dynamic, intuitive and cost-effective working environment were immersive and symbiotic collaboration between human workers and robots can take place and bring significant benefits to robot-reluctant industries (where current tasks and processes are thought too complex to be automated). The benefits that the project can bring about include lower costs, increased safety, better working conditions and higher profitability through improved adaptability, flexibility, performance and seamless integration. This project is planned for 48 months with a consortium of 15 partners from 7 EU Member States.

Development of key technologies to address a new wing design for a HER aircraft maturing up to TRL5: manufacturing, assembly, structural concepts and processes, concept studies, configuration and architecture trade offs for a full wing component are part of the activity. As a physical demonstration concept, the detail design and manufacturing of the relevant components of a centre wing section of a HER Aircraft will be addressed. Conceptual wing studies: configuration and architecture (structural arrangement, Systems allocation and disposition, flight control system) trade offs for a full wing. Full wing structural arrangement mock up for innovative wing concepts, Structural and Multidisciplinary Optimization studies for definition of the optimal structural configuration of wing. Demonstration platform: wingbox, high lift devices, control surfaces, load alleviation devices focusing on the centre section as a demonstration platform: - Integrated Centre section wing box structure with the inner Propulsion stage: Full span (pylon to pylon) torsion box concept representative of more ambitious tip 2 tip concept. Multispar concept, Access manholes and panels, Sustainable aviation fuel and Integrated Fuel vent systems. - Inner section Leading Edges, Integrated Inductive ice protection system integration, Multifunctionality: erosion, impact, Lightning, ice protection, Morphing concepts, Functional tests, Bird strike tests (virtual or real) - Inner section Flap and high lift solutions: Integrated flap solutions. Multifunctionality application to flap. Key processing technologies: Low cost-high integrated out of autoclave technologies. Dry fiber placement and liquid resin infusion for integrated multispar torsion box. Thermoplastic composites processing: In situ consolidation for integrated flap skin and Leading edge applications. Thermoplastic welding and co-consolidation for Integration. Bonding technologies exploration towards certifiable solutions.