The aim of the IntAir project is to refine the materials and upscale the manufacturing process for a new generation of aircraft interior composites that are cheaper, lighter and safer than the toxic, carcinogenic materials that are currently used. To meet the strict fire and weight requirements for aircraft interiors, the current solution is to use a fire-resistant composite made of phenolic resin with glass fibre reinforcement. However: - Phenolic parts are expensive due to long moulding times and need several hours of manual finishing. - The poor surface finish means that filler is needed, adding to the component weight - Phenolics have a poor health and safety footprint, as they emit toxic and carcinogenic materials during processing As a direct substitute for phenolic, this project focusses on a composite using polyfurfuryl alcohol (PFA), which gives cost, weight and safety benefits over phenolics: - A 34% reduction in moulding cycle time, and a 70% reduction in manual finishing, giving a 58% cost reduction over phenolics - PFA gives a significantly improved surface finish, reducing the use of filler by 70% and reducing average component weight by 4% - PFA composites are non-toxic, non-carcinogenic, eliminating health & safety concerns from the workplace Testing by prospective customers has shown that PFA composites can meet aircraft interior standards for mechanical and fire performance. However, the development has so far been limited to simple formulations on small-scale, prototype equipment which does not yet give the accuracy or scale needed. The overall objective of this project is therefore to improve the processability, optimise the properties and upscale the production process of PFA composites for aircraft interiors. Addressing these 3 issues will enable significant improvements in part cost, component weight and worker safety compared to phenolics, and will allow the material to be commercialised on aircraft manufacturing programmes.

OntoTrans provides an ontology-based Open Translation Environment. Its Artificial Intelligence approach enables end users to represent in a standard ontological form their manufacturing process challenges and to connect them with relevant information sources and materials modelling solutions, capable to support optimal materials and process design. OntoTrans provides smart targeted guidance through the whole translation process, namely from the initial user case specification to actual materials modelling workflows with related validation, verification and uncertainty quantifications to deliver a full complete experience to companies. This is achieved via analysis of available data (data fusion), modelling workflow options, simulation and contextual results interpretation. OntoTrans is fully integrated into existing and emerging developments in materials and manufacturing, including integration with digital materials modelling marketplaces and open simulation platforms. Its footing on the European Materials Modelling Ontology ensuring wide interoperability and standardisation. OntoTrans is developed and tested alongside four industrial challenges covering different types of materials and industries, targeting increased competitiveness by means of a semantic data-driven and agile approach.

To reduce society's dependence on petroleum based non-renewable polymers, large scale utilization of naturally occurring, abundantly available polymers such as cellulose needs to be developed. One of the major challenges in large scale utilization of cellulose from biomass is dissolution and processing of cellulose to prepare downstream products such as high performance textile fibres. The Viscose method is the most common way to manufacture cellulose fibres; however, it is a complex, multistep process which involves use of very aggressive chemicals and requires a large volume of fresh water. In the 1970s, petroleum based synthetic polymer fibres such as polyester and nylon were commercialised and were proven to be more economical than producing cellulose fibres via the Viscose method. Hence, the production of cellulose fibres was reduced from over 1.3 million tons per year in 1973 to 0.4 million tons per year by 2008 (Source: International Rayon and Synthetic Fibres Committee). To overcome this issue of processing of cellulose we are proposing to develop an environmentally benign method of manufacturing of high performance cellulose fibres using "Green Solvents". The proposed research will help develop sustainable and high performance cellulose fibres which can in-principle replace heavy glass fibres (which requires high energy during its manufacturing) and non-renewable polymer precursors used for manufacturing of carbon fibres which are widely used in composites for aerospace, auto, sports and wind energy industries in UK and abroad.

Polyurethane (PUR) products, which include foams for building, construction, automotive and furniture and bedding, are petroleum-based and usually lack important properties. The need for sustainability in these industries leads to the development of cost-efficient processes and sustainable added-value products from low carbon footprint materials. The main objective of BIOMAT is to establish an Open Innovation Test Bed (TB) for the benefit of industries and SMEs, aiming to facilitate the cross-border partnership and accelerate innovation in nano-enabled bio-based insulation materials for these industries. Through the creation of a Single-Entry Point (SEP), SMEs and other industrial parties will have open access at a competitive price to physical facilities (pilot production lines) and services (characterisation, nanosafety, standardisation/regulation, business/marketing plans as well as technological and business-oriented mentoring) which will be focused on manufacturing and testing of nanoparticle-enabled functional PUR-based foams for the above mentioned industrial sectors. The SEP will follow all EC guidelines related to the establishment of new entities providing services through different testbeds across Europe. BIOMAT ecosystem will cover the entire Value Chain (VC) from fundamental biomaterials and functional nanoparticles to the final products and their proof of concept in an industrial environment, thus accelerating the market uptake of the new nano-enabled sustainable bio-based products. BIOMAT will, therefore, fill the existing gaps in the VC of these industrial sectors, by providing new services and support at different levels the use of such materials in these key industries.

The increasing demand for low and zero carbon buildings in the UK has provided significant challenges for the energy intensive materials we currently rely on. At present somewhere between 20% and as much as 60% of the carbon footprint of new buildings is attributable to the materials used in construction; this is predicted to rise to over 95% by 2020. If the UK is to meet agreed 80% carbon reduction targets by 2050 it is clear that significant reductions in the embodied carbon of construction materials is required. What also seems clear is that current materials and systems are not capable of delivering these savings. The drive for an 80% reduction in carbon emissions, a decreasing reliance on non-renewal resources and for greater resource efficiency, requires step changes in attitude and approach as well as materials. Improvement in construction systems, capable of providing consistently enhanced levels of performance at a reasonable cost is required. Modern developments in construction materials include: eco-cements and concretes (low carbon binders); various bio-based materials including engineered timber, hemp-lime and insulation products; straw based products; high strength bio-composites; unfired clay products utilising organic stabilisers; environmentally responsive cladding materials; self healing materials; smart materials and proactive monitoring; hygrothermal and phase change materials; coatings for infection control; ultra thin thermally efficient coatings (using nano fillers); ultra high performance concretes; greater use of wastes; and, fibre reinforcement of soils. However, very few of these innovations make the break through to widespread mainstream use and even fewer offer the necessary step change in carbon reductions required A low carbon approach also requires novel solutions to address: whole life costing; end of life (disassembly and reuse); greater use of prefabrication; better life predictions and longer design life; lower waste; improved quality; planned renewal; and greater automation in the construction process. As well as performance, risk from uncertainty and potentially higher costs other important barriers to innovation include: lack of information/demo projects; changing site practices and opposition from commercial competitors offering potentially cheaper solutions.. A recent EPSRC Review has recognised the need for greater innovation in novel materials and novel uses of materials in the built environment. The vision for our network, LIMES.NET, is to create an international multi-disciplinary community of leading researchers, industrialists, policy makers and other stakeholders who share a common vision for the development and adoption of innovative low impact materials and solutions to deliver a more sustainable built environment in the 21st Century. The scope of LIMES.NET will include: adaptive and durable materials and solutions with significantly reduced embodied carbon and energy, based upon sustainable and appropriate use of resources; solutions for retrofitting applications to reduce performance carbon emissions of existing buildings and to minimise waste; climate change resilient and adaptive materials and technologies for retrofitting and new build applications to provide long term sustainable solutions. In recognition of their current adverse impacts and potential for future beneficial impacts, LIMES.NET will focus on bringing together experts to develop pathways to solutions using: renewable (timber and other plant based) construction materials; low-impact geo-based structural materials; cement and concrete based materials; innovative nano-materials and fibre reinforced composites. Through workshops and international visits the network will create a roadmap for multidisciplinary research and development pathways that will lead to high quality large research proposals, and an on-going virtual on-line centre of excellence.