To extend the usage of the metal and LPBF powders (LPBF is a technique used for metal 3D printing), as well as allow re-use of thermoset prepreg and thermoplastic production waste in aerospace sector, the SUSTAINair project aims to investigate:

  • The impact of SHM sensors on recycling
  • Near-net shape metallic process development as well as near-net additive manufacturing of metallic components
  • Inhouse recycling from cast housing production scrap
  • Inter-recycling of wrought (solid form) or cast (liquid form) alloys
  • Upcycling of thermoset prepreg production waste material
  • Upcycling of thermoplastic production waste
  • Characterisation of new recyclate materials
  • Life Cycle Assessment in compliance with ISO14040:2006

The outcomes are new up- and recycling technologies to reduce Buy-to-Fly (BTF) ratio, saving substantial amounts of virgin material and with it associated costs.

Additionally, the SUSTAINair project aims to cut down on waste-streams in manufacturing by enabling inhouse reuse of scrap i.e. runner from casting, used Additive Manufacturing (AM) powder, uncured thermoset remainder of prepregs; thermoplastic short fibre feedstock.

SUSTAINair outcomes:

  • Up to 75% cost reduction versus current 1st life composite materials
  • 10-20% weight decrease
  • Up to 100% recyclability versus negative effects from downcycling, pyrolysis or landfill of current thermoset FRPs (Fibre-reinforced plastic).