>10000 wind turbine blades (WTBs) were installed in Europe in 2019, and the largest are >100 m long. Yet the manufacturing methods have not changed significantly since the 1970s, with little or no NDT or in-line control, leading to high defect, repair and scrap rates. TURB0 will reduce defects and improve repair strategies in WTB composites and coatings. -Improved composite production processes: By using the latest simulation techniques to avoid defect formation and understand how defects affect structural integrity. -In-line NDT: Combining three cutting-edge NDT technologies (dielectric, wireless, sensor-less) for the first large scale in-line in situ composite production monitoring. -Sub-surface WTB coating inspection: Currently coatings only undergo visual surface inspection or destructive testing. TURB0 will combine ultrasound and mid-IR OCT for the most detailed coating assessment ever performed. -Digital twin and data warehouse: Production equipment, monitoring and in-line NDT data will be combined to establish a digital twin for real-time analysis of production. This has never been attempted for a large-scale composite part. It will populate a data warehouse accessible from multiple production sites. -In-line system control: Using the digital twin, a ML-based algorithm will provide closed-loop process control to minimise defect formation and waste and optimise process efficiency. -Automated repair strategy: The digital twin enables a ML analysis of defect severity in composites, with automated strategies to reduce repairs by 90 % and increase recycling of off-cuts. -Full-scale demo: A demo on a full size >80 m WTB section will be performed at the SGRE factory in Aalborg. -Quantified sustainability improvements: including life cycle analysis (LCA), social LCA and circular economy assessments to quantify environmental and socioeconomic benefits. -Dissemination and exploitation activity: includes a powerful Advisory Board, training, standards and business plan.

Europe is on an ambitious path to becoming climate neutral by 2050, aiming to cut 55% of greenhouse gas (GHG) emissions by 2030. Transport is a sector where so far it has proved harder to reduce emissions, while being one of the main energy users and source of emissions. Transport sectors such as aviation heavily depend on high energy density fuels, for which sustainable biofuels are the best near term low-carbon renewable alternative. Biofuel production based on algae is being considered as a main clean energy alternative and one of the most promising solutions. However, there are several challenges that hinder development and application of algae-based biofuel, ranging across the entire value chain. SUSTEPS main overall objective is to improve key knowledge, identify systemic constraints and opportunities, and propose solutions for the scaling up of a sustainable algae-based biofuel value chain. It aims to contribute to cost-effective and more sustainable large-scale production of sustainable algae-based biofuels by developing and validating a bio-refinery concept that efficiently produces sustainable biofuel from non-food/feed microalgae via CO2 fixation from high-emission facilities and through feeding on nutrient-rich wastewater, thereby minimising biomass production costs and utilising harmful CO2 emitted from energy-intensive activities. The process will be coupled with green hydrogen to be used in upgrading of microalgae-based fuel, and smart integration of processes that also produce value-added chemicals, valorising all side streams effectively. Based on international collaboration, SUSTEPS will build a more efficient, less costly CO2-to-biofuels process, identifying systemic constraints, opportunities and solutions for scaling up the value chain of algae-based sustainable biofuels which will support the development of best practices and concepts along the entire value chain and accelerate the scale-up of sustainable biofuels worldwide.

OCT is a key imaging technology, allowing non-contact high resolution 3D imaging which has helped to save the sight of millions of people. However, progress has stalled since reaching the axial resolution (dz) limit of 1 um. Quantum OCT (QOCT) offers a step change x2 improvement in dz and greatly reduces dispersion. In addition, control of orbital angular momentum (OAM) reduces noise and improves edge and surface profile definition and discrimination of chiral objects. SEQUOIA will deliver the highest resolution OCT system ever built, protected from noise by artificial intelligence (AI) based OAM control in a real-world application: retinal imaging. Underpinning SEQUOIA is an ultra-stable, ultra-low noise comb source of unprecedented bandwidth (250-400 nm) which builds on NKT’s world-leading supercontinuum sources and adds new PTB techniques for stabilisation and noise control. AI-based algorithms (UPV) will be used at TUD to program spatial light modulators to encode high purity high-dimensional OAM onto the QOCT beams to increase resilience to noise and improve imaging quality. MPD will deliver new single-photon avalanche diode arrays specifically tailored for quantum imaging, to perform photon coincidence correlation at an unprecedented rate. NOR’s world-leading classical OCT software will be extended to create the first ever QOCT software. Theoretical work at NCU will develop the first mathematical models of noise in QOCT to optimise the spontaneous parametric downconversion. PTB will perform metrological characterisation of all relevant parameters and DTU will quantify the QOCT advantage over classical OCT. Retinal imaging using stable test standards from WWU will be performed, with automated AI-algorithms (UPV) to compare performance with classical OCT. ARD will perform a detailed techno-economic and social life cycle analyses to evaluate future markets and impacts. VIV will coordinate an extensive dissemination programme with a high-profile Advisory Board.

The METAMORPHA concept is a single agile USP laser micromachining platform to replace many conventional manufacturing process chains. It has the potential to eliminate thousands of environmentally damaging production processes. METAMORPHA is all-electric, all-digital, produces no waste chemicals and enables novel processes for product rework and repair. All-in-one module: The key to this agility is a combination of two cascaded spatial light modulators (SLM) and a galvo scanner resulting in the most sophisticated beam shaping and steering ever developed. This allows a single module to perform the job of several laser processing heads: e.g. polishing, milling, drilling and cutting (importantly including any wall angle). Made-to-measure laser processes: Each infeed component is scanned with a high resolution 3D sensor. A machine learning algorithm determines an individualised laser process to maximise efficiency and ensure "first time right". In-line process control: Data from additional online sensors are processed using an edge device running a self-learning algorithm to provide real-time feedback for system control. The ultra-fast edge-based signal processing and synchronisation are key project topics. Agile and scalable: Suitable for any standard industrial production line including 2-, 3- or 5-axis, rotating and roll-to-roll, and for scale up to parallel processing with multiple modules. The three end use cases (UCs) show the versatility and scope for replacing existing process chains: UC-1 PHILIPS: Small complex metal parts (shaving heads) requiring 90 degree wall angles. UC-2 TKSE: Large area embossing rollers and the re-writing of old rollers. UC-3 CERAT: Very hard carbide parts and refurbishment of worn parts. Sustainability assessment: A life cycle analysis (LCA) and social LCA will be carried out to quantify the environmental and socioeconomic benefits. A detailed plan for exploitation and an extensive dissemination and communication plan are in place.

The AQUABIOPRO-FIT main objective is to promote efficient utilisation of European aquaculture, fisheries and agriculture side streams in feeds and nutritional supplement products promoting fitness and health. To this end, we will develop side stream biomass processing technologies to up-concentrate nutrients and bioactives maintaining product quality and minimising waste. The safety, bioactivity and acceptance of the developed ingredients and products will be documented through cell, animal, taste panel and intervention studies with humans, namely athletes and patient groups. Technical, marketing, economic and environmental studies will complement the documentation portfolio of the AQUABIOPRO-FIT concepts and products. The developed knowledge and principles will be further systematised in net-based training modules, which will follow the intellectual property rights of the developed methods and products. Information material will be created for educating the public and raise awareness of the importance of circular economy and promote acceptance for side stream bio-based products in end markets.