LAY2FORM will create a new cost-effective multistage manufacturing platform based on flexible machinery concepts, cognitive automation, inline monitoring and inspection, as well as simulation and modelling, enabling the efficient integration of unconventional technologies (laser and ultrasound) in established composites-based processes, namely tape-laying and hot-forming, to enable the production of multifunctional 3D hybrid parts from thin layered metals and thermoplastic-matrix composites. Framed by an end-to-end engineering approach, LAY2FORM will shorten the design and manufacturing cycle time and improve reliability, presenting a substantial potential to, in the middle term, turn the manufacturing of complex and intricate hybrid composite-metal parts highly cost competitive. The enhanced LAY2FORM manufacturing system will be a system of systems, containing the enabling process modules and digital sub-systems to create a continuous and automated manufacturing chain. Moreover, LAY2FORM will apply an integrated and systemic approach to implement full manufacturing routes and create new value chains, from materials conditioning to materials disassembly, being a robust basis for the efficient production of hybrid lightweight structures. The multidisciplinary approach proposed in LAY2FORM comprises a complex interconnection of leading R&I topics to develop an industrially-feasible and competitive manufacturing platform, compatible with the Industry 4.0 vision.

The manufacturing of large-scale parts needs the implementation of a holistic data management and integrated automation methodology to achieve the desired levels of precision using modular and more flexible equipment. Large-part manufacturing is characterized by the high customization required (built-customer specific). Also, manufacturing of complex large-scale parts involves a variety of subassemblies that must be manufactured and assembled. This high degree of personalization implies a great effort in the design and the posterior verification after manufacturing, to achieve high precision. On the other hand, this customised product-centric design requires an optimisation of the resources of the workshop –i.e. workers, machines, devices— for a responsive, reconfigurable and modular production, targeting the execution of key labour-intensive tasks by preserving industry-specific workers’ knowledge and skills (worker-centric approach). PENELOPE proposes a novel methodology linking product-centric data management and production planning and scheduling in a closed-loop digital pipeline for ensuring an accurate and precise manufacturability from the initial product design. PENELOPE is built over five pillars for developing a common methodology and vision deployed in four industrial-driven pilot lines in strategic manufacturing sectors (Oil&Gas, Shipbuilding, Aeronautics and Bus&Coach) and with potential replicability to other sectors. Moreover, it will be set a pan-European network of Didactic Factories and showrooms, providing training and upskilling capabilities enabling the workforce transition towards Industry 4.0 and general-purpose testbeds for assisting in the industry adoption. PENELOPE envision to highly-increase EU manufacturing sector competitiveness by increasing production performance, quality and accuracy while ensuring workers’ safety and resource efficiency.