MULTI-FUN sets a clear focus on market-creating innovation, developing advanced materials and equipment for Additive Manufacturing of multi-material parts. These new material combinations will provide a significant performance & efficiency gain in MAM products by fully integrated multi-functionalities based on novel active materials and enable MULTI-MATERIAL design in geometrically complex 3D metal parts without size limitations by innovative, cost-effective AM technologies. The novel integrated functionalities include embedded electrical conductivity, fibre-optical sensing features or innovative heat management concepts, incl. applying nanotechnologies in at least 3 variants. Leading experts in AM process & equipment manufacturing (from SMEs, IND, RTOs and UNIV) will fully cover the physical integration of these advanced materials into metallic substrates. Significant improvements in efficiency, quality & reliability of products will result in KPI numbers beyond the request (>40%), alongside reduced environ

Metal halide perovskite solar cells have moved into the focus of energy materials research through impressive power conversion efficiencies. However, the most efficient perovskite absorbers contain toxic lead. Tin halide perovskites have emerged as a highly promising alternative and efficiencies up to 14.6% have been already reported, but to become a highly efficient thin film technology, further increasing their efficiency and stability, as well as fast and homogeneous large area perovskite crystallization compatible with roll-to-roll processes are still major hurdles. These challenges are tackled within SMARTLINE-PV by the development of a fast, robust and scalable plasma assisted crystallization technology leading to high quality tin perovskite films. The benefits lie in the high speed of the process, the low temperatures involved and in the precise control of perovskite nucleation and growth by a combination of the precursor chemistry and the plasma conditions. Moreover, (i) tailored interlayers will be applied to further improve the solar cell efficiency and stability and (ii) novel device concepts to fabricate flexible tin perovskite solar cell modules with selectable colour will be implemented. The lead-free thin film PV technology developed in SMARTLINE-PV will achieve efficiencies of 25%, with significant reduction of energy consumption and manufacturing costs compared to other thin film technologies, which typically involve high temperature steps. For the SMARTLINE-PV consortium, these advancements will lead to a plethora of new opportunities to strengthen the European photovoltaics industry in many sectors including the important building-integrated (BI) PV market. Ecodesign, circularity and social acceptance will play important roles in the whole development process in which a TRL progression of tin perovskite solar cells to TRL 5 is foreseen, which will be validated by the fabrication of BIPV-demonstrators and their operation in real-life conditions.

Multiple challenges exist with respect to the development of multifunctional and intelligent airframe and engine parts. These are situated along the entire aircraft component value chain - design, manufacturing, MRO and recycling. SUSTAINair addresses each of these phases. With respect to design, new joining techniques for metal and composite designs are developed and demonstrated. For metal joining, these include a novel pin-pattern creation with Laser Powder Bed Fusion/Wire Arc Additive Manufacturing/Laser Direct Energy Deposition. For composites, these consist of thermoplastic welding. With respect to both design and manufacturing, a flexible wing with morphing capabilities is made industrially possible by introducing a novel concept using tailored elastomers, seamless integrated with conventional structural wing parts for lowest integration risk, providing a realistic industrial morphing technology. The problem of high production waste in the manufacture of composite materials, Ti AM and Al HPDC is addressed, thereby reducing waste streams, e.g.: For thermoset prepreg manufacturing waste and thermoplastic waste, new recycled materials are developed and characterized to allow re-use with recyclability up to 100%, bringing FTB ratio close to 1 (KET3-KPI); Increased BTF ratio of Ti powders by using it 6x (vs. 1x now) (KET4-KPI); Incredible BTF ratio <1.1 by advanced HPDC processing of thermal stable nano-eutectics (KET5-KPI). A Structural Health Monitoring system optimizing MRO activity is proven using radically new ZnO nanowires, which will be integrated into polymer as well as metal parts. Finally, SUSTAINair raises the bar with respect to aircraft EoL, introducing Industry 4.0 automated technology for robotic dismantling.