Project

About the project

In the aerospace industry the reinforced composite materials are more and more demanded, where the end-of life (EoL) of the final product aspect is very debated point nowadays. The thermoplastic materials play a key role because of their recycle properties. This fact can bring about a challenge to design recycling techniques to extend the EoL of the reinforced composite parts. However, any of this current recycling methods can recover by 80% of the thermoplastic (TP)fibre and ensure the acceptable mechanical properties of the rCF(recycled carbon fibre). The project will provide a solution by developing a recycling method for the key process steps: scrapping by cutting mechanic, automatic deposition and compression moulding manufacturing. The selection of the most suitable recycling process will be based on the previous studies performed by the partners and a comparison with the state of the art of the TP recycling techniques. Then, the scrap material obtained in UD tape format(50x6.0.15mm3)will be deposited automatically with a robot collaborative resulting a preform panel which will be manufactured by compression moulding means. The automation advantage will allow to reduce the labour cost and the manual defects. The estimated cost per kilo of the scraped material will be 0.37€/kg, a very competitive cost for a real alternative to a high cost material(> 30€/kg).

The consortium consists of all key players that will play a future role in the recycling and manufacturing of TP rCF composites. AIMPLAS will play a leading role in the consortium as far as the recycling methods in thermoplastic composites is concerned. This knowledge will be complemented by TEKNIKER with a vast experience in experience in the design and manufacturing of special cutting tools. The project will conclude with the environmental and economical LCA analysis of the innovative process proposed and an eco-design guideline of recommendations for the scalability of the process in an industrial level.

Objectives

Main objective at SPARTA

SPARTA project aims at designing and manufacturing a novel and eco-efficient scrapping methodology of reinforced fibre structures in order to approach the dimensions required for compression moulding manufacturing of high-quality parts producing a significant lower percentage of dust than conventional grinding technologies.

The technical objectives of SPARTA project are the following:

Objective 1. To achieve a scrap curvature lower than 10º that allows the easy desposition of the tape in the mould and futher manufacture the recycled TP carbon fiber reinforced by compression moulding.
A commercial CAE software will be used to simulate the effect of the tape deformation in the final properties of the compression moulding parts, based on previous studies at lab test experiments with a microtome decives. The ultimate goal of the process is to get flat scraps, this is, zero curvature. However, the generated scrap is likely to be curved in a certain amount.
Objective 2. To design and manufacturing a cutting tool capable of generate chips of 50x6x0.15 mm3 with a difference in dimensions lower than 5% under the curvature threshold defined.
Objective 3. To design a cutting tool capable to produce up to 32 kg/h of chopped tapes and with an energy consumption lower than 0,35 kWh/kg of chopped tapes
Objective 4. Cutting tool with a OPEX and CAPEX no more than 130% of current mechanical grinding processes.
Objective 5. To develop a quality process deposition of the UD tapes in order to produce a stable panel and reduce the manual work about 20% per composite part production
Objective 6. To update the database of CleanSky 2 ECO Transverse Activity (TA)
Objective 7. To produce a procedure and an eco-design guideline of the SPARTA recycling process suitable for an industrial level
The SPARTA project is committed with the H2020 challenges developing a more efficient manufacturing process respectful with the environment by means of decreasing the environmental impact and cost during the production of the aircraft parts. The main enocnomic, strategic, environmental progress resulting form SPARTA the to meet the objectives of the project are listed the following table:

Area Driver Objective

REDUCING COST

Develop a suitable scrapping process. The investigation of new methods of scrapping to improve the current management of thermoplastic structures reinforced with carbon fibre at the end of the product life, will contribute in the future air transport to considerably reduce the environmental impact of all operations related to aviation systems: virgin material production, composite manufacturing and recycling.
The use of an appropriate tool for TPC (Thermoplastic Composite) scrapping can ensure the size of the scrap tape curvature of the fibre in order to fit similar mechanical properties to the original fibre.
Turn worthless scrap material into valuable raw material
Reused raw material suitable for compression moulding at an affordable price. TPC scrapping is cheaper than virgin raw material production for TPC manufacturing. A kilogram of recycled carbon fibre is valued at around US$ 15 while the price of virgin carbon fibre is US$ 24-305 making the recycling of the carbon fibre a real necessity. What is more, Airbus TIER 1 has set a target of recycling of tis carbon fibre waste by 2020-25, with 5% recycled back to the aerospace sector. Therefore, recycling initiatives will have a greater role in the upcoming composite market under a responsible use of natural resources. Increase the demand of reused raw material
Recover the waste parts generated during the TPC manufacturing process in order to produce the kg of scrap necessary to introduce it again into the production line. No need of raw material adquisition

ECO-DESIGN

Due to the use of the scrapped material, some design concepts such as the fibre/volume content, the size/weight and flake distribution need to be measured and optimised in order to ensure the mechanical properties of the new high quality composite parts. Re-design of composite part to achieve similar properties to the virgin ones
The integration of the improved environmental aspects in the manufacturing processes of aviation, through the reduction of waste material, the reduction of emissions, the reduction of consumption of primary resources and the increase in recycling rates.

EFFICIENT MANUFAC-TURING

The complete characterization of the scrapped material will allow to optimize the recycling technique to products suitable for use in the compression moulding process manufacturing. Optimization of the recycling techinique
The use of a colaborative robot will allow to remove the manual deposition operations and make sure that a defect-free preform is transferred to the compression moulding process. Optimization of the tapes deposition
An online temperature control system through sensors of the compression moulding process will allow to optimize the cycle time providing a high quality composite part. Optimization of the compression moulding cycle
Reduction of energy consumption because of the number of steps and time in the scrap obtaining. Reduction of energy consumption

TIME TO MARKET

The use of scrapping material will allow to reduce the time to market of new aviation products due to the fact that: 1) the dependence of the availability (considerable delivery times and storage capacity) and the price fluctuations of virgin raw materials suppliers (a few companies around the word) and 2) the compression moulding process has a fast processing time . Reduce the production time due to material availability at unchanged price

QUALITY

Design a suitable scrapping tool to obtain in an automatic way small 0.15mm thick tapes to enable the correct and automatic positioning of the UD tapes on the mould to achieve comparable properties than the ones obtained using virgin materials. TP composites parts with similar properties to virgin ones

Results

Consortium

AIMPLAS

AIMPLAS

València Parc Tecnològic Calle Gustave Eiffel, 4 46980 Paterna Valencia, ESPAÑA
Tekniker

Tekniker

C/ Iñaki Goenaga, 5 20600 Eibar Gipuzkoa - Spain

SPARTA at media

  • Tekniker crea una solución de reciclaje para aeronáutica

    02/12/2022
    esTRATEGIA empresarial
  • Reciclar composites termoplásticos de aeronaves

    08/11/2022
  • Una nueva solución de reciclaje para la aeronáutica de Aimplas permite reaprovechar hasta el 80% de termoplásticos

    08/11/2022
  • AIMPLAS desarrolla un proceso de reciclaje aeronáutico para reaprovechar hasta el 80% de los termoplásticos

    08/11/2022
    Metales y metalurgia NW
  • Reciclar composites termoplásticos de aeronaves

    08/11/2022
    Mundoplast - NewsLetter
  • El complejo último vuelo del ingente escuadrón de aviones desechados

    07/11/2022
    ABC
  • El complejo último vuelo del ingente escuadrón de aviones desechados

    06/11/2022
    ABC
  • Una nueva solución de reciclaje para la aeronáutica deAimplas permite reaprovechar hasta el 80% de termoplásticos

    04/11/2022
  • Aimplas desarrolla un proceso de reciclaje aeronáutico para reaprovechar hasta el 80% de los termoplásticos

    04/11/2022
    Metales y metalurgia NW
  • Una nova solució de reciclatge per a materials termoplàstics

    02/11/2022
    El Periódico Mediterráneo
  • Aimplas promoverá la reducción del impacto medioambiental de productos farmacéuticos durante su ciclo de vida

    02/11/2022
  • Una nueva solución de reciclaje para la aeronáutica de Aimplas permite reaprovechar hasta el 80% de termoplástico

    02/11/2022
  • AIMPLAS Y TEKNIKER CREAN UNA METODOLOGÍA QUE APROVECHARÁ LOS MATERIALES TERMOPLÁSTICOS DE LA AERONÁUTICA

    02/11/2022
  • El proyecto SPARTA crea una solución para reciclar hasta el 80% de los termoplásticos del sector aeronáutico

    02/11/2022
  • EL PROYECTO SPARTA CREA UNA SOLUCIÓN PARA RECICLAR HASTA EL 80% DE LOS TERMOPLÁSTICOS DEL SECTOR AERONÁUTICO

    02/11/2022
  • AIMPLAS y TEKNIKER crean una solución de reciclaje para la aeronáutica que reaprovecha hasta el 80% de residuos

    31/10/2022
  • AIMPLAS acelera el reciclaje de materiales termoplásticos en aeronaves

    31/10/2022
    RETEMA - NewsLetter
  • AIMPLAS crea una nueva solución de reciclaje para la aeronáutica que permite reaprovechar hasta el 80% de los materiales termoplásticos

    31/10/2022
  • Una nueva solución de reciclaje para aeronáutica permite reaprovechar hasta el 80%

    28/10/2022
  • AIMPLAS crea una nueva solución de reciclaje para la industria aeronáutica

    28/10/2022
  • Una nueva solución de reciclaje para aeronáutica permite reaprovechar hasta el 80% de los materiales

    27/10/2022
  • Una nueva solución de reciclaje para aeronáutica permite reaprovechar hasta el 80% de los materiales

    27/10/2022
  • AIMPLAS acelera el reciclaje de materiales termoplásticos en aeronaves

    27/10/2022
  • Solución de reciclaje para la aeronáutica que permite reaprovechar hasta el 80% de los materiales termoplásticos

    27/10/2022
  • Una nueva solución de reciclaje para aeronáutica permite reaprovechar hasta el 80% de los materiales

    27/10/2022
  • Advanced Manufacturing Madrid 2022 presenta el mayor programa de contenidos y actividades de su historia

    29/07/2022
  • El programa de Advanced Manufacturing Madrid 2022

    26/07/2022
  • Advanced Manufacturing Madrid 2022 presenta el más completo programa de contenidos y actividades

    25/07/2022
  • Advanced Manufacturing Madrid 2022 presenta su programa de contenidos

    14/07/2022
  • Advanced Manufacturing Madrid 2022 presenta el mayor programa de contenidos y actividades de su historia

    14/07/2022
  • Método de reciclagem inovador para compostos termoplasticos

    02/02/2022
    Interplast
  • Método de reciclagem inovador para compostos termoplásticos

    19/10/2021
    INTERPLAST
  • Método de reciclagem inovador para compostos termoplásticos

    01/10/2021
    Interplast
  • Materiales sostenibles para el sector de la movilidad

    01/10/2021
    Revista Plásticos Modernos papel
  • AIMPLAS starts research to develop more efficient methods of recycling composite materials

    30/09/2021
  • Aimplas inicia investigação para desenvolver métodos mais eficientes de reciclagem de materiais compósitos

    30/09/2021
  • Un metodo innovativo di riciclo per compositi termoplastici

    07/04/2021
    Compositi magazine
  • Reciclagem química se desenvolve com base em muita pesquisa

    19/01/2021
    Plastico Industrial
  • AIMPLAS begins research on developing more efficient methods of recycling composite materials

    04/01/2021
  • El proyecto europeo SPARTA reducirá los residuos e impactos ambientales generados por la industria aeronáutica

    04/01/2021
  • Se inician las investigaciones para desarrollar nuevos métodos eficientes de reciclado de materiales compuestos

    04/01/2021
  • AIMPLAS inicia las investigaciones para desarrollar nuevos métodos eficientes de reciclado de materiales compuestos

    04/01/2021
  • Research to develop more efficient methods of recycling composite materials

    04/01/2021
  • El proyecto europeo SPARTA obtendrá una nueva metodología para el reciclado y reprocesado de materiales composites termoplásticos que reducirá el volumen de residuo generado en la industria aeronáutica y su impacto medioambiental así como diseñar métodos de fabricación más eco-eficientes

    04/01/2021
  • AIMPLAS INICIA LAS INVESTIGACIONES PARA DESARROLLAR NUEVOS MÉTODOS EFICIENTES DE RECICLADO DE MATERIALES COMPUESTOS

    04/01/2021
  • El proyecto SPARTA obtendrá una nueva metodología para el reciclado de composites termoplásticos

    04/01/2021
  • El proyecto europeo SPARTA reducirá los residuos e impactos ambientales generados por la industria aeronáutica

    04/01/2021
  • El proyecto europeo SPARTA reducirá los residuos e impactos ambientales generados por la industria aeronáutica

    04/01/2021
  • El proyecto europeo SPARTA obtendrá una nueva metodología para el reciclado y reprocesado de materiales composites termoplásticos

    04/01/2021
  • El proyecto europeo Sparta

    31/10/2020
    Mundoplast
  • Efficient methods to recycle composite materials

    28/09/2020
  • AIMPLAS focuses on more efficient composites recycling

    28/09/2020
  • Aimplas starts research to develop more efficient methods of recycling composite materials

    28/09/2020
  • AIMPLAS starts new research project to develop more efficient methods of recycling composite materials

    28/09/2020
  • Se inician las investigaciones para desarrollar nuevos métodos eficientes de reciclado de materiales compuestos

    24/09/2020
  • AIMPLAS inicia las investigaciones para desarrollar nuevos métodos eficientes de reciclado

    24/09/2020
  • Sparta: avanzar en el reciclado de composites

    22/09/2020
  • AIMPLAS inicia las investigaciones para desarrollar nuevos métodos eficientes de reciclado de materiales compuesto

    22/09/2020
  • Aimplas coordina el proyecto 'Sparta'

    21/09/2020
  • Aimplas investiga nuevos métodos de reciclado de materiales compuestos para reducir residuo en la industria aeroespacial

    21/09/2020
  • AIMPLAS desarrolla nuevos métodos eficientes de reciclado de materiales compuestos

    21/09/2020
  • Aimplas y Tekniker desarrollan nuevos métodos de reciclado de materiales compuestos

    21/09/2020
  • Aimplas investiga nuevos métodos de reciclado para reducir los residuos en la industria aeroespacial

    21/09/2020
  • Aimplas investiga nuevos métodos de reciclado de materiales compuestos para reducir residuo en la industria aeroespacial

    18/09/2020

      

This project has received funding from the European Union’s Horizon 2020 research and innovation programme for the Clean Sky Joint Technology Initiative under grant agreement No 887073.