BIOcomposites in smart plastic transformation processes to pave the way for the large-scale UPTAKE of sustainable bio-based products

Project Information

BIO-UPTAKE

Grant agreement ID: 101057049

DOI

10.3030/101057049

Project closed

EC signature date 8 December 2022

Start date 1 December 2022

End date 31 May 2026

Funded under

• Digital, Industry and Space

Total cost

€ 6 495 326,25

EU contribution

€ 6 495 323,50

Coordinated by

FUNDACION AITIIP
Spain

Periodic Reporting for period 2 - BIO-UPTAKE (BIOcomposites in smart plastic transformation processes to pave the way for the large-scale UPTAKE of sustainable bio-based products)

Reporting period: 2024-06-01 to 2025-05-31

Summary of the context and overall objectives of the project

The general objective of Bio-Uptake project is to ensure a sustainable uptake (increase the use in a 39%) of bioplastic composites through boosting a twin green and digital transformation in the European manufacturing industry. In particular, Bio-Uptake solution will focus scientific and technology efforts on developing flexible manufacturing processes to produce biobased end-products for the construction, medical and packaging sectors based on the combination of intermediate formats made of natural and/or biobased synthetic fibres reinforced with biopolymers, which are easily adaptable to new market demands. The novel approach on which Bio-Uptake project relies is based on modularity or pre-fabrication: a smart combination of intermediate formats (organosheets, tapes and pellets) into a final end-product which allows to overcome the current technical and environmental limitations to meet the demanding requirements of a specific sector/application where a single biobased material doesn't. Thus, the synergistic potential of composite materials will pave the way for the integration and uptake of bio-based materials in mass customised manufacturing (manufacturing as a service). Three disruptive manufacturing processes (based on conformal technologies) will be developed within Bio-Uptake focused on the plastics manufacturing sector, which is on the centrality of a variety of value chains, and being demonstrated in 3 demo cases (bathroom ceiling cabinet, feet orthosis and garbage container lid). Sustainability criteria will be applied since the design phase to reach circularity by design, obtaining products with more than 75% biobased content and decreasing GHG up to 33%.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the first 30 months of the project, the technical work has been mainly focused on developing the intermediate products in WP2 and developing manufacturing processes in WP3, both finalised at the end of the second Periodic Report. As a result, the consortium obtained self-reinforced filaments, thermoplastic UD tapes and organosheets, thermoset organosheets, dynamic chemicals and pellets. All the techniques were adapted to the use of bio-based materials: bioPA, PLA, flax fibres... Final optimised batches of these intermediate products were manufactured, characterised and sent to end-user partners in WP3. The in-line monitoring activities of the intermediate formats finalised and deployed. Additionally, the three manufacturing processes, thermoset thermoforming, thermoplastic thermoforming and one shot over-injection molding were completely developed and adapted to biobased materials during this period (WP3). The environmental and human safety of the intermediate and final products was be assessed. The modelling of the three processes was also developed, as well as the in-line quality systems. Finally, the Bio-Uptake digital platform was completed and deployed also during this period.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The novel approach on which Bio-Uptake project relies is based on modularity or pre-fabrication: the development of high-tech biobased intermediate formats (organosheets, tapes and pellets). The smart combination of these intermediates into a final end-product allows to overcome the current technical and environmental limitations to meet the demanding requirements of a specific sector/application where a single biobased material doesn´t. Thus, the synergistic potential of composite materials will be multiplied by the possibility of combining different intermediate formats to pave the way for the integration and uptake of bio-based materials in mass customised manufacturing (manufacturing as a service). Moreover, Bio-Uptake solution does not involve major machine modifications and large investment in complex equipment, but rather it involves the development of peripherals and the adaptation of simulation models to the intrinsic characteristics of biomaterials.
Three different manufacturing processes will be developed within Bio-Uptake (from the twin green and digital perspective) focused on the plastics manufacturing sector, which is on the centrality of a variety of value chains. These processes are designed to address diverse kinds of bio-based composite materials, including thermoset or thermoplastic polymers reinforced with natural fibres (including carbon positive materials).
1. Ceilings for bathroom pods: Semi-automated process to produce endured pre-impregnated organosheets and thermoforming of the sandwich structure with the balsa core. Flax fabric pre-impregnated with Biobased 3RCANs-Epoxy (from Vanillyl alcohol – DGEVA, coming from lignin)+ wood core with bonding-debonding reversible adhesive 30% faster process. Reprocesable and Recyclable. Storable at room temperature → No scraps (no value lost in the VC)
2. Feet insoles: Consolidation of layers (organosheets and UDTapes) anatomically structured in a one-shot free forming (press consolidation + thermoforming). Only a final trimming is required. PLA and PCL (mono and multi component), which has the particularity of once the final shape is ready, it can be warmed up if necessary, for an anatomical adaptation (which cannot be done with epoxy, GF or CF). Reusability and Recyclability. 34% more efficient, 12% lower costs, 50% shorter process and allows to put biobased materials that otherwise is unfeasible....)
3. Lid for garbage containers: Conforming of self-reinforced PLA organosheet & overinjection of reinforced bioPolyamide (short lignin-Carbon and wood fibres). This hybridization will enable to reduce by 35% the final weight of the lid and by 22% the plastic material used. BioPA will ensure the lid to withstand outdoors environment & the application of a reversible adhesive on the organosheet´s surface will ensure materials´ separation for remanufacture and recycling.