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Agency: Cordis | Branch: FP7 | Program: CP-TP | Phase: FoF.NMP.2013-11 | Award Amount: 5.41M | Year: 2013

Volume production at industrial scale of miniaturised multi-material 3D (polymer-polymer, metal-polymer, metal-metal, polymer-ceramics,...) still face important challenges to be affordable by SMEs. Challenges not only in terms of precision manufacturing (precision engineering <0.01%) but also in the adequate interaction between the different constituent materials. Besides multi-material micro-system manufacturing processes still show to be time and cost consuming mainly from assembling activities and back en processes (35-60% of the total manufacturing costs come only from the assembling), so further research efforts in alternative and more integrated manufacturing concepts(over-moulding of micro-components and in-mould assembly technology would avoid the assembly step) are needed. To answer those problems the development of high-throughput and cost-efficient process chains based on micro injection should consider the following aspects: Improved volume production, not only from the standpoint of the necessary accuracy and performance of the process, but also regarding the interaction/bonding of the different materials which make up the produced parts and the possibility of selective functionality of their surfaces. The integration of the different processes including the feeding and handling systems for automatic operation in order to eliminate human intervention and manufacturing costs. Analyse the most suitable process control, online verification and back-end processes taking into account the features of the multi-material replicated parts represented by five demonstrators. The aim is to reduce manufacturing costs up to 40%. Thus, the HINMICO project final outcome will enable to produce high quality multi-material micro-components through more integrated, efficient and cheaper process chains.

Agency: Cordis | Branch: FP7 | Program: CP-TP | Phase: NMP.2012.4.0-1 | Award Amount: 3.71M | Year: 2013

The demand for aesthetically integrated photovoltaic materials is increasing steadily in many industries. A growing number of designers, architects and industrial manufacturers across the world share a common interest in using Photovoltaics (PV) as a decentralized and sustainable source of energy in their product designs. Developing markets such as sustainable housing, temporary building structures, outdoor activities, electro-mobility and mobile computing will drive the demand for decentralized, attractive energy solutions. For solar powered products are customisable shapes, sizes, colours, transparencies or specific electrical properties required, which have a decisive influence on the acceptance on the market. Therefore a new breed of solar technologies is necessary. To achieve this goal new flexible production processes and materials need to be developed. A novel manufacturing process will enable the adjustment of all properties of a thin-film module on-the-fly and facilitate the production of customized photovoltaic modules with the desired voltage, size and shape. Combined with the material characteristics given by the underlying thin-film solar cell technology a new-breed of design-led, sustainable and decentralised energy solutions can be realized. Furthermore the designer or architect who wants to incorporate solar electricity into his work needs a service environment to be assisted in the creative process. Tools should support the designer in conceiving, planning and producing the solar design products. This project will address the above mentioned challenges by exploring and developing new materials, manufacturing and business processes in PV powered product design and architecture.

Agency: Cordis | Branch: H2020 | Program: IA | Phase: WASTE-1-2014 | Award Amount: 9.28M | Year: 2015

The main vision of CABRISS project is to develop a circular economy mainly for the photovoltaic, but also for electronic and glass industry. It will consist in the implementation of: (i) recycling technologies to recover In, Ag and Si for the sustainable PV technology and other applications; (ii) a solar cell processing roadmap, which will use Si waste for the high throughput, cost-effective manufacturing of hybrid Si based solar cells and will demonstrate the possibility for the re-usability and recyclability at the end of life of key PV materials. The developed Si solar cells will have the specificity to have a low environmental impact by the implementation of low carbon footprint technologies and as a consequence, the technology will present a low energy payback (about 1 year). The originality of the project relates to the cross-sectorial approach associating together different sectors like the Powder Metallurgy (fabrication of Si powder based low cost substrate), the PV industry (innovative PV Cells) and the industry of recycling (hydrometallurgy and pyrometallurgy) with a common aim : make use of recycled waste materials (Si, In and Ag). CABRISS focuses mainly on a photovoltaic production value chain, thus demonstrating the cross-sectorial industrial symbiosis with closed-loop processes.

Agency: Cordis | Branch: H2020 | Program: SME-2 | Phase: Space-SME-2014-2 | Award Amount: 950.00K | Year: 2015

The main goal of this project is the development of an industrial plug & play system for additive layer manufacturing which is based on a blown powder process using Plasma Transferred Arc (PTA) Technology. The developed 4M System will offer: a) Simple equipment concept based on well established PTA technology for hard facing coatings b) Possibility to realize Multi-Material concepts c) Suitability of the technology to be used for a wide range of raw materials d) High deposition/building rates e) Possibility to realize large size components (up to 1,5 m x 1,5 m in the first version) Within the project the system will be developed to be used for wo different materials (Al and Ti-alloys) and to demonstrate one multi-material concept. The developed process will be used to realize three different demonstrators (case studies) and to perform testing of the manufactured prototypes under space relevant testing conditions.

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