Large engineering structures like turbines, bridges or industrial machinery are still manufactured by traditional processes such as forging, casting or by machining from solid blocks. These processes do not allow local control of material properties to achieve a specific function like anti-corrosion or hardness. To meet the functional specifications, engineers must operate within a limited range of design options, with high “buy-to-fly” ratios and long lead times. Unlike any other metal AM technology, wire arc additive manufacturing (WAAM) produces fully dense metallic structures with no porosity. WAAM is also unbeatable in terms of production times, making it uniquely suited for large and functionally demanding engineering structures. In Grade2XL, we will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large scale structures. The high printing rate of WAAM, combined with the ability to control material properties down to the nanoscale, will allow us to build strong and durable engineering structures. Grade2XL will deliver multi-material products of superior quality and performance, cut lead times by up to 96% and enable massive cost savings for the maritime and energy industry, as well as for industrial machinery. These outputs will rapidly roll out to other sectors with similar key performance indicators and become an attractive investment opportunity for SMEs. This project will strengthen Europe’s capacity to drive manufacturing innovation globally and withstand growing competition from Asia.

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.

The HELENUS project will build, integrate and demonstrate a 500kW solid oxide fuel cell (SOFC) module operating in cogeneration (combined heat and power) mode, in an MSC World class series ocean cruise vessel. The SOFC will be fully integrated- spatially, electrically, and thermally- into the ship design. SOFCs are the most efficient chemical energy converters available today, and are also highly fuel-flexible- thereby remaining highly relevant for the future of waterborne transport. The HELENUS demonstrator will achieve a TRL of 7 at the end of the project, with extended field testing already planned to reach TRL8 by 2028-2029. Success of this project will enable upscaling of mature SOFC technology in ocean cruise liners to as high as 20MW, by as early as 2029. This can unlock over 23% total fuel savings (assuming a hybrid 20MW SOFC+60MW ICE energy system) over a state-of-the-art energy system with only ICEs. The HELENUS consortium involves diverse and accomplished stakeholders representing the entire value chain from technology development to field implementation- creating a rapid pathway towards exploitation and commercialisation. HELENUS will also undertake extensive simulation, experimental (using an 80kW scaled-down SOFC module), and analytical efforts to demonstrate the applicability of the developed SOFC solution (i) upon significant scale-up (10 MW and beyond), (ii) over duty cycles of alternate applications such as dredging- and offshore- vessels, and (iii) using carbon-neutral fuels with potential for future maritime uptake. Experimental results will be complemented by application case- and lifecycle performance- analyses to assess the broader impact of the technology on waterborne transport. Therefore, HELENUS creates a technological and regulatory roadmap towards a maritime future with scaled-up clean energy systems operating on renewable fuels – thereby fostering innovation and significantly boosting the competitiveness of the EU maritime industry

Ro-ro ships are an important component of the global transportation system, but an increasing trend of ro-ro ship fires in recent years call for improved fire protection. From comprehensive ship operators’ experience and by participation in ongoing work for the European Maritime Safety Agency and the International Maritime Organization (IMO), critical aspects of ro-ro ship fire safety have been identified to form the scope of the project LASH FIRE. It aims to provide a recognized technical basis for the revision of international IMO regulations, which greatly enhances fire prevention and ensures management of fires on ro-ro ships without recourse to external intervention. This is done by developing and demonstrating operational and design solutions which strengthen the fire protection of ro-ro ships in all stages of a fire and which address current and future challenges, including regulatory issues. Twenty specific challenges have been identified, which will be addressed by new solutions developed and demonstrated with regards to performance and ship integration feasibility by system suppliers, researchers, ship owners and shipyards. For the solutions to be considered for regulatory uptake, their impact on risk reduction and cost will be assessed and advisory groups with operators and flag states will be established. Thereby, the project is expected to significantly strengthen the independent fire protection of ro-ro ships and to reduce the frequency of ro-ro ship fires by 35% and the number of fatalities by 45%.

The main objective of the FIBRESHIP project is to create a new EU-market to build complete large-length ships in FRP (Fibre-Reinforced Polymers) enabling its massive application. In order to achieve this objective, the project will develop, identify and qualify FRP materials for different applications in particular for long-term structural strength and fire resistance. In addition to this, its massive application also requires elaborating innovative design procedures and guidelines supported on new validated software analysis tools. Standardized efficient production methodologies will be implemented and demonstrated by delivering a proof of concept. Clear performance indicators will be designed and applied in the evaluation of three targeted vessels categories (container ship, ferry and fishing research vessel) to be developed within the project. The project will also analyze the life cycle cost benefits of incorporating FRP materials in large-length ships, developing a business plan for the different actors in the value chain. The business plan will cover the different phases of the life cycle from design, engineering, material production and shipbuilding to the final dismantling of the vessel. The use of FRP materials in large-length ships will imply a significant weight reduction (about 30%) and a relevant impact in fuel saving, ship stability, environmental impact (reducing greenhouse gas emissions and underwater noise), and increase of cargo capacity. On the other hand, FRP materials are immune to corrosion and have a better performance under fatigue type loads, what means better life performance and reduced maintenance costs. The mid-term impact is estimated in about 5% of the total shipbuilding market in Europe (turnover about €2.0Bn), and it is envisaged a long term impact of up to 54.000 new direct jobs. Furthermore, it is estimated that the European shipping companies could deduct up to €1Bn/year cost with the adoption of the proposed FRP shipbuilding technology.