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 OR additive manufacturing of metallic components (near-net)?
- 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.
- 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).