SUSTAINair - circular economy for the aviation and aerospace sectors

4R´s of circular economy: Redesign, Repair, Reuse, Recycle

The waste of high-quality, aerospace-grade materials is one of the biggest challenges to sustainable aerospace engineering. SUSTAINair applies circular economy principles to the design, manufacturing, operations and end-of-life phases of aircraft. This includes:

  • Circular design of individual components and joining technologies for airframe construction (including morphing)
  • Real-time structural health monitoring of materials and joints during operations
  • Improved maintenance and repair technologies to extend aircraft life time
  • Rivet removal demonstrator using robotics and water jet cutting for improved recovery of high-quality aluminium recycling materials

Welcome to the SUSTAINair project – enabling green transition of the aviation and aerospace sectors. 

SOLUTIONS FOR CIRCULAR AVIATION

The SUSTAINair project gives the aviation sector a transition runway to a low-carbon, competitive economy while tackling the increase in resource consumption, waste and emissions along the entire aviation component value chain. 

Explore circular approach to different stages of aircraft life-cycle by clicking on the stage of interest.

Integration of novel sensors enabling real-time, onboard damage diagnosis and prognosis (SHM)

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Economically viable automated aircraft fuselage dismantling and material separation

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Novel techniques to re-use aluminium, titanium-based powders for metal 3D printing, thermoset prepreg and thermoplast production waste, automatized separation of alloys.

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Joining and repair technologies for similar and dissimilar aerospace grade material combinations.

Closing the gap between material purchased and material used: buy-to-fly ratio

Cost saving through zero-waste assembly

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Lightweight design meets up-and recyclable materials and embedded functionalities for real-time structural health monitoring.

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SUSTAINair SOLUTIONS FOR CIRCULAR AVIATION

The SUSTAINair project gives the aviation sector a runway to transition into a low-carbon competitive economy while tackling the increase in resource consumption, waste and emissions in industries along the entire aviation component value chain

EVOLUTION OF EUROPEAN POLICY FRAMEWORK

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Flightpath 2050 Europe’s Vision for Aviation

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European Circular Economy Action Plan (CEAP)

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European Green Deal

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Circular Economy Action Plan for a Cleaner and More Competitive Europe

CREW

Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
EASA´s advisory role in SUSTAINair is focused on certification, regulation, and safety assessment aspects thus reducing the time to market of new innovative products and business models while adhering to the high level of safety, security, and environmental protection.
Willy Sigl, EASA
Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
The SUSTAINair project demonstrates that the environmental challenges are an opportunity for technological advancement. I hope we can pay our dues as well as inspire the generations that follow.
Chiara Bisagni, TU Delft
Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
I am proud to be part of the team in a pan-European project contributing to greener aviation, with an ultimate goal: zero emissions! Clearly, such an international challenge cannot be tackled without European collaboration.
Ruben Nahuis, NLR
Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
Metallic 3D printing and bonding concepts for metal/fibre reinforced plastic joints are two challenging topics we at DLR can address in SUSTAINair. I cannot wait to apply the design freedom that 3D printing gives us to new, effective bonding solutions.
Miriam Löbbecke, DLR
Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
I’m inspired by the 11 partners in the SUSTAINair project who want to contribute to the greening of aircrafts by developing new technologies for repairable and variable wings, the bonding of different lightweight materials, sensors for structural monitoring and maintenance and reconditioning.
Reinhard Kaindl, JOANNEUM
11th EASN Christoph Kralovec at EASN presenting SUSTAINair Predictive analytics for sustainable aviation
SUSTAINair allows my team and me at JKU to support a more sustainable deployment of raw materials by working towards replacement of today’s scheduled maintenance and withdrawal from service of structural components by a condition-based approach – thus changing the industry standard.
Christoph Kralovec, JKU
Maximilian Stummer _ INOCON _SUSTAINAIR H2020
SUSTAINair enables us to apply our patented atmospheric plasma processing on sensor material for novel structural health monitoring systems. Such challenges are what drives us to innovate.
Maximilian Stummer, INOCON
Aircraft performance, Circular economy, 4Rs of circular economy, Design, Manufacturing, MRO, Maintenance, Composite Materials, Aerospace, Aviation, Carbon emissions
SUSTAINair is pursuing very holistic and complex approach of circular economy practices tailored to the aeronautic context. This makes this H2020 project uniquely exciting to be a part of while considering its potential for a real and lasting impact.
Marc Joulian, INVENT GmbH

H2020 PROJECT SUSTAINair

SUSTAINablility increase of lightweight, multifunctional and intelligent airframe and engine parts

Jan 2021
Aug 2022
Dec 2023
Dec 2023
June 2024
June 2024
START
Testing phase
Database with test results
Life Cycle Analysis
DEMO
END

COORDINATOR

The SUSTAINair project is coordinated by AIT-LKR (Austria).

FUNDING

The SUSTAINair project is funded by the H2020 programme, under EU.3.4. - SOCIETAL CHALLENGES - Smart, Green And Integrated Transport, as a RIA - Research and Innovation action.

PROJECT PARTNERS

The SUSTAINair project is collaboration of 11 partners from industry and academia.

WHAT'S NEW

How INOCON’s Plasma Technology is Helping Us Innovate Circular Aviation

How INOCON’s Plasma Technology is Helping Us Innovate Circular Aviation

Founded in 1994, INOCON is a specialist in manufacturing machinery for various plasma-based welding and brazing techniques, of vital importance…
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We Need More Than Just Lightweight Design | Exploring Circular Aviation with NLR

We Need More Than Just Lightweight Design | Exploring Circular Aviation with NLR

Rising to the circular aviation challenge of reducing environmental impacts while remaining economically viable is naturally a complicated task, filled…
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New SUSTAINair publication identifies efficient approach for damage detection in aerospace sandwich structures

New SUSTAINair publication identifies efficient approach for damage detection in aerospace sandwich structures

In a new publication, SUSTAINair partner JKU has identified a new, efficient approach for strain-based damage detection in aerospace composite…
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AELS joins SUSTAINair project

AELS joins SUSTAINair project

The SUSTAINair consortium is glad to announce that AELS (Aircraft End-of-Life Solutions) has joined the project as a partner. This…
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