TOOL4LIFE
TOOLing materials, design, and process engineering, leading to improved sustainability and wider applications for the composites of tomorrow
| Business | Period | Project Coordinator | Funding Scheme |
|---|---|---|---|
| Industry | August 2022 - July 2025 | Bercella |
LIFE-2021-SAP-ENV-ENVIRONMENT |
Challenge
Composite materials find their greatest potential in the applications where low weight, high mechanical performances and precise, near-net-shape production is required. The fields of application are many and varied, however their sustainability is still a major concern.
TOOL4LIFE was conceived to address the issues of sustainability in a fundamental pre-processing step for the composite manufacturing: the application of tooling as moulds for the composite manufacturing.
The project aims to design and manufacture tooling completely recyclable in thermoplastic materials with hybrid technology (AM followed by milling and in-mould coating), substituting the not-recyclable thermosetting material currently used. During the project new water-based formulations for in-mould sealant, demoulding and finishing agents will be developed to reach a fully retrofittable and recyclable solution.
The process will enable the use of 20% to 25% polymer material, reducing up to 80% the volume of material used, 33% less energy and will emit only the 9,2% of the CO2 equivalent against the current benchmark.
TOOL4LIFE has received funding from the European Union’s Programme for Environment and Climate Action (LIFE) under grant agreement N° 101074299 for the call “Circular Economy and Quality of Life - Standard Action Projects (SAP) (LIFE-2021-SAP-ENV)”.
Approach
RINA gives engineering support for the modelling of the mechanical performances of the AM parts and the shape optimization to address the issue of tooling lightweight design, and sustainability assessment in the end-products.
Furthermore, RINA will conduct the activities related to the assessment of the market opportunities and models of business, as well as the assessment of the environmental, economic and societal sustainability and coordinate the activities of dissemination and exploitation of project results.
Conclusion
In conclusion, TOOL4LIFE will develop an innovative solution for the manufacturing of tools used in composite manufacturing. Tools will be made of recyclable materials developed in the project, with composition and properties that do not impact the possibility to reuse it at the end of its life to produce new tools. Within the project, the developed optimized processes both for the tools manufacturing and for the retrofit process will be validated.
The new solution will be optimized in terms of material and energy use, it will be fully recyclable and adaptable. In this way TOOL4LIFE will actively contribute to the reduction of CO2 emissions, energy saving, landfilling, and the creation of healthier world for citizen.
