Multimaterial systems combining metals with thermoplastic fiber reinforced polymer composites (TP-FRPC) are the key for light weight design in the automotive industry. However, the joining of the material partners remains main issue. Currently, no approach exists which sufficiently meets the three core requirements: weight neutrality, cost- and time efficiency and bonding strength. Technologies like adhesive bonding or bolted joints show good results for one or two of the criterions, but not for all three of them. The FlexHyJoin project aims at the development of a joining process for hybrid components, which satisfies all three criterions. Induction Joining (IJ) and Laser Joining (LJ) are combined, since they have complementary fields of application and most of all they do not require additional material and are therefore weight neutral joining methods. Thus, the full lightweight potential is preserved. Additionally, a surface texturing method for the metal is integrated in the approach, which leads to a form closure bonding, providing a high mechanical bonding performance. Finally, a main aspect of the FlexHyJoin project is to integrate the surface texturing as well as both joining methods in a single, continuous, and fully automatized pilot process with an overall process control and supervision system. This leads to a maximum of time- and cost-efficiency and will allow the future application of the approach in the mass production of automotives. The key for the automation is an online process control and quality assurance. The FlexHyJoin project provides an essential enabler technology for future mobility concepts. The final result is an innovative joining process for fiber reinforced polymers and metals, suiting the strict requirements of automotive industry and enabling the broad application of hybrid material systems.

Glass and carbon fiber reinforced polymer composites (GFRP and CFRP) are increasingly used as structural materials in many manufacturing sectors like transport, constructions and energy due to their better lightweight and corrosion resistance compared to metals. Composite recycling is a challenging task. Although mechanical grinding and pyrolysis reached a quite high TRL, landfilling of EoL composites is still widespread since no significant added value in the re-use and remanufacturing of composites is demonstrated. The FiberEUse project aims at integrating in a holistic approach different innovation actions aimed at enhancing the profitability of composite recycling and reuse in value-added products. The project is based on the realization of three macro use-cases, further detailed in eight demonstrators: Use-case 1: Mechanical recycling of short GFRP and re-use in added-value customized applications, including furniture, sport and creative products. Emerging manufacturing technologies like UV-assisted 3D-printing and metallization by Physical Vapor Deposition will be used. Use-case 2: Thermal recycling of long fibers (glass and carbon) and re-use in high-tech, high-resistance applications. The input product will be EoL wind turbine and aerospace components. The re-use of composites in automotive (aesthetical and structural components) and building will be demonstrated by applying controlled pyrolysis and custom remanufacturing. Use-case 3: Inspection, repair and remanufacturing for EoL CFRP products in high-tech applications. Adaptive design and manufacturing criteria will be implemented to allow for a complete circular economy demonstration in the automotive sector. Through new cloud-based ICT solutions for value-chain integration, scouting of new markets, analysis of legislation barriers, life cycle assessment for different reverse logistic options, FiberEUse will support industry in the transition to a circular economy model for composites.

Islands are characterized by massive touristic flows concentrated in specific high-season Islands are characterized by massive touristic flows concentrated in specific high-season peaks, temporarily amplifying the local consumption of products and the consequent generation of waste materials. ReBoat aims at designing, developing and demonstrating a novel decentralized systemic circular solution focused on plastics and textile, exploiting a mobile, modular, sorting, recycling and reprocessing plant on a Boat that will transform local waste into new products, meeting the needs of island citizens, tourists and local artisans and workers. Three complementary pilots at Eolian, Ioninan and Azores islands, will CoCreate new objects, spaces and experiences through an Island Participatory Approach supported by Collaborative Digital tools, by the Boat technical infrastructure with recycling and reprocessing machineries onboard, and by Artists, working-holidays Students, and Designers who will animate a 2 weeks event in each pilot engaging people. Newly designed Tourism Packages will empower the engagement and enrich the offering, promoting conscious and sustainable holidays in European Islands. 15 partners from 7 Eu Member States, experts in heterogeneous and complementary sectors will cooperate to demonstrate the feasibility of the 6 innovation pillars and to provide a concrete experience to citizens and tourists that will be made publicly available through training materials, success stories, open access data. Replicability will be studied with the objective to obtain a concrete exploitation after the project ends. The project will obtain results in the following innovation pillars: a Boat for local recycling, the digital solutions for the CoCreation and scheduling in exploitation, the new touristic packages and signed agreements, the generation of new circular products to be sold, the engagement of local stakeholders and PAs, and the definition of the final business model.

The urgency to address the environmental impact of the prevailing linear economic paradigm has intensified, stressing the need for optimizing resource utilization, minimizing waste, and maximizing product value to achieve ecological and economic benefits. This is particularly critical in the automotive industry, where a significant volume of primary materials is employed. Recycling scrap materials in this sector can yield impressive 85% reduction in CO2 emissions. However, designing automotive parts for circularity requires innovative (1) tools and infrastructures to close current information gaps as well as (2) multi-purpose alloys with enhanced compatibility and processibility for scrap materials to increase recyclability of materials. This requires a comprehensive consideration of life cycle scenarios, potential constraints on recycled material, and adherence to changing standards and regulations. Digi4Circular project tackles these challenges by creating a robust digital workflow for circular product development integrated into the Synera low code platform, demonstrated on aluminium casting use case in the automotive sector. Through automated workflows, the project facilitates the generation of circular product designs and manufacturing possibilities, contingent on environmental impact assessments for different end-of-life scenarios. The approach relies on novel methods for material design and property prediction of circular alloys, rapid LCA and LCC analysis, knowledge extraction from norms and expert know-how, integrated by rule- and knowledge-based systems for automated product design generation. The workflow connects all necessary software tools and data generated throughout the value chain in a dedicated information space, whereas life cycle data for individual products is systematically stored in a Digital Product Passport accessible for all developers in the value chain.

ZEvRA's main objective is to improve the circularity of light-duty EVs throughout their entire value chain, from materials supply and manufacturing to end-of-life (EoL) processes, which aligns with the European Union's goal of achieving zero CO2e emissions by 2035, particularly in the EV value chain. To do so, ZEvRA will develop a Design for Circularity (DfC) methodology and a holistic circularity assessment aimed at improving the production of electric vehicles (EVs) based on the 9Rs. This methodology will be validated by developing zero emission solutions for the most important automotive materials, covering > 84% material mix: steel, three versions of aluminium (wrought, casting, and foam), thermoplastics composites (long and continuous fibre-reinforced), unfiled/short fibre plastics, glass, tyres and Rare Earth Elements (REE). These solutions will be supported by a set of digital tools to support the manufacturing of the use cases, the assessment of circularity, traceability, and the virtual integration of components into a full replicable vehicle. To maximise the outreach of our methodology and zero emission solutions, ZEvRA will develop a dedicated training & upskilling programme for the automotive workforce and academia, together with activities aimed at increasing awareness & acceptability of the proposed zero emission solutions. Lastly, circular business models targeting EoL and logistics aimed at improving the economic feasibility of circularity in EVs are advanced. ZEvRA’s innovations aim to improve zero emission approaches in the life cycle and value chain of at least 59% of European EVs by 2035 through the 5 OEMs and Tier 1’s that are part of the consortium, which includes industry and academia covering the entire automotive value chain.