The reduction of manufacturing waste is a key challenge to achieve a EuropThe reduction of manufacturing waste is a key challenge to achieve a European transition towards climate neutrality and the goals of the Green Deal. In this context, to achieve the zero-defect manufacturing paradigm has becomes a must for those European productive companies that wants to take the step towards sustainable production. Composites play an important role in strategic European manufacturing sectors like energy, aerospace, naval or automotive, with a growing forecast. So, FLASH-COMP project will develop a human-oriented solution, capable of identifying in an early-manner feasible defectiveness in composite parts manufacturing and to determine if corrective actions should be adopted. All with the ultimate goal of optimizing the composite manufacturing process, reaching zero-defects and consequently, reducing the generation of waste ?process and product associated. FLASH-COMP will develop non-destructive inspection and monitoring instruments to retrieve key process parameters. Will develop an on-line Defect Severity Estimation Tool that will predict the appearance of defects and will estimate their severity to suggest the optimum Feedback and Feedforward control strategies. And will develop a decision support system. In addition, an interoperable software platform for data-sharing will be created. The full FLASH-COMP solution will be demonstrated in a test bed, enabling the experimental validation of the FLASH-COMP concept, and 2 industrial use cases, assuring its future replicability, and paving the way for a future exploitation of results. FLASH-COMP will include a complete skills development training program since the FLASH-COMP solution has been conceived to assist the operator in controlling and making decisions about the manufacturing process. Finally, the project will deal with the development of a standardization roadmap, to ensure the widest possible impact of project results

The main goal of FLOWCAASH project is to design and manufacture reliable and safe flow control actuators at aircraft scale by Selective Laser Melting (SLM) able to withstand the high temperatures (up to 260 °C) and pressures (5 bar) during flight test with aerodynamic performance and high resistance to harsh environments. FLOWCAASH project is focused on the development of innovative designs of Active Flow Control (AFC) actuators to be manufactured by powder bed based additive manufacturing (AM) using Ti6Al4V alloy. Selective Laser Melting (SLM), that utilizes a laser as a thermal energy source to melt the powder has been chosen as the preferred AM technology. The innovative designs of these AFC actuators will allow to be installed in restricted space in the next generation aircrafts with UHBR (Ultra High Bypass Ratio) engines. Two different actuators will be considered, Pulsed Jet Actuator (PJA) and Steady Blowing Actuator (SBA). These actuators will have the potential to reduce aerodynamic flow separation and to increase lift coefficient. This will be obtained by bionic design which allows complex geometries and improve structural strength while reducing the weight. In order to assure process reliability of large Ti parts, distortion prediction numerical simulations will be accomplished. As-built part will be post-processed by means of heat and surface treatments in order to ensure dimensional stability and adequate surface quality for aerodynamic performance. Afterwards the actuators will be validated by aerodynamic and harsh environment tests including rain, icing, sand and dust, vibrations and anti-icing fluid. The FLOWCAASH project will be developed by a well-balanced consortium that brings together 2 partners: the research center LORTEK and the aerospace test laboratory CTA.

AMALTEA’s main objective is to streamline the use of robotics, AI and data in the construction sector to reduce the energy use, resources and waste, increase safety, and improve processes’ reliability and product quality to adapt to the new demands from end users and Green Deal objectives. For that, the curtain-wall façade value chain will be reshaped by digitalizing the design, manufacturing, installation and disassembly/recycling phases. This approach is supported by the development and combination of several digital tools that will be integrated, together with technical solutions provided by SMEs and start-ups through FSTP, in Digital Solutions that will be validated in four pilots to improve the sustainability, efficiency, safety and automation of the façade value chain, and thus, building construction. The global solution will consider human in the loop for collaborative robotics and will use existing technologies to guarantee the safety use of the data across the entire process. Piloting will include: 1) AI parametric design and extended digital twin with all the data workflows along the façade value chain, 2) Digitalized façade manufacturing line in FDB facilities in Hungary, 3) and 4) Implementation of the solutions in operational construction environments (Residential/Hospital typology in the South of Europe and Offices/Tertiary typology in the Center of Europe). The project involves companies from all necessary disciplines, including: design, AI and data, robotics, manufacturing, construction, SSH (to have special care related to the communication between humans and the technologies developed). Additionally, the project will establish a collaboration with external SMEs (up to 25 projects) across Europe through a FSTP scheme to improve all the challenges defined.

Thermography opens a new paradigm because shifts actual manual inspections like those of Fluorescent Penetrant Inspection (FPI) into automated inspection and detection to avoid human errors. AUTHENTIC addresses the development and adoption of automated inductive active thermography to improve the probability of detection (POD) of surface defects generated or appearing in welded safety-critical engine components both for in-process control and for final inspection and quality acceptance. The high sensitivity of the technology enables the detection of cracks down to 200 μm. An improvement higher than 50% is expected on the detectable critical defect size, on POD basis. Automation will be implemented during the inspection process through an adequate robotic system and also during the defect detection, characterization and localization, thanks to the developed algorithms. Furthermore, a second sensory will be added to the main system in order to tackle geometrically complex cases where thermography might fail or give a partial result due to accessibility issues. The system developed will provide (i) faster inspections on full-scale components, (ii) elimination of human subjectivity from inspections, and (iii) healthier and cleaner working environment for technicians. The easier, faster and more accurate maintenance inspections will lead to safer aircrafts and to the extension of their lifetime contributing to a globally more innovative, sustainable and competitive EU aircraft industry. AUTHENTIC will cover from the complete definition of the NDT system based on process and inspection requirements to its implementation and validation through the inspection of a real component provided by GKN (topic leader). The achievements of project objectives will be supported by the multidisciplinary consortium formed by experts in thermography (LORTEK, ULEOEBEN and EDEVIS), simulation (ULEOBEN), automated inspection (EDEVIS), sensorics (HV) and welding metallurgy (LORTEK, HV).