JOANNEUM RESEARCH: Advances in Eco-Friendly Manufacturing Innovations

MATERIALS, the Institute for Sensors, Photonics and Manufacturing Technologies at JOANNEUM RESEARCH, has been very successful in the current Horizon Europe call TWIN GREEN AND DIGITAL TRANSITION 2023. MATERIALS is coordinating the strategically important “MULTIMOLD” and “WAVETAILOR” projects, thereby achieving a particularly high level of visibility throughout Europe in the field of sustainable production technology and laser technology.

“As a result of this call, JOANNEUM RESEARCH is the only European organisation coordinating two strong international consortia in the field of production technologies. In addition to the welcome funding that we are able to attract for our business partners and ourselves as a result, we are finally establishing ourselves at the forefront of the European research landscape,” says MATERIALS Director Paul Hartmann, summarising the success. The volume of both projects amounts to around 10 million euros. 2 million euros of this will go to JOANNEUM RESEARCH, while a further 1.6 million euros will be channelled into the research of the other Austrian project partners.

Innovations in in-mould electronics

Injection moulded electronics (IME) technology is an advanced manufacturing technology that allows electronic circuits and components to be integrated directly into plastic housings or structures by injecting or inserting them into the plastic part during the moulding process. This is a proven method for producing three-dimensional parts with integrated graphics.  These processes have expanded to include functional printing of circuits and sensors and are now being used in areas such as the automotive industry, power generation and healthcare. Despite a high yield in most sub-processes, the efficiency of the overall process is a maximum of 85%. This poses problems in terms of costs and sustainability, as current products require high complexity and multiple materials that are difficult to recycle, therefore not compatible with the goal of a sustainable circular economy. In addition, limitations are observed such as the inadequate functioning of sensors in wet conditions and the lack of haptic feedback. The MULTIMOLD (Multi-functional In-Mould Electronics) project aims to overcome these challenges by developing an innovative manufacturing process for durable, recyclable and multifunctional electronic products based on the principle of “circularity by design”. As part of the project, the experts at MATERIALS in Weiz will continue the successful integration of PyzoFlex® sensors in in-mould electronics components from the recently completed Smart@Surface project.

Project partners: JOANNEUM RESEARCH Forschungsgesellschaft mbH, R2M SOLUTION SRL, INTERUNIVERSITAIR MICRO-ELECTRONICA CENTRUM – IMEC, MONTANUNIVERSITÄT LEOBEN, STANDEX INTERNATIONAL SRL, NANOGATE CENTRAL AND EASTERN EUROPEPE GMBH, SCHNEIDER ELECTRIC INDUSTRIES SAS, EOLOGIX SENSOR TECHNOLOGY GMBH, SYXIS VSI, FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV, HTP HIGH TECH PLASTICS GMBH

Contact: jonas.groten@joanneum.at, elena.turco@joanneum.at

WAVETAILOR sets new standards in efficient production technology

The WAVETAILOR project (Modular laser sources for sustainable production of short personalised production series) is dedicated to the innovative production of 3D-printed components from multi-materials for two key sectors: the aerospace industry, in particular for hypersonic aircraft that are to be powered by hydrogen, and drone technology for delivery in urban areas. A central concern here is defect-free, sustainable first-time-right-production that fulfils the high requirements. The focus is on developing an energy-efficient photonic system based on modular laser sources and optics that can utilise different wavelengths (innovative diode lasers). Diode lasers are 20 to 30 % more energy efficient than conventional laser technologies. This means that powder bed-based 3D printing processes (L-PBF) and laser metal deposition (L-DED) are more energy-efficient, component quality is improved and the number of metal-based material types that can be processed can be increased. The use of digital twins makes first-time-right production possible. The AI models developed in the process learn the cause-and-effect relationship between the production parameters and component quality from the recorded production data and suggest improvement measures in production planning. This reduces waste, energy consumption and production costs. The successful implementation of innovative technologies is expected to reduce energy consumption by 200 MWh and produce almost 1000 kg less waste, while at the same time reducing production costs by 50-65%. These sustainable benefits are to be confirmed by a comprehensive sustainability study.

JOANNEUM RESEARCH experts are contributing their expertise in L-PBF technology to the project and feeding the AI models with process experience. They are also working on the process parameters for aluminium and titanium using diode lasers and will create demo components.

Project partner: JOANNEUM RESEARCH, LORTEK S COOP, PRIMA ADDITIVE SRL, NLIGHT EUROPE SRL, Z PRIME GMBH, DESTINUS SPAIN, AEROTECNIC METALLIC SL, MORPHICA SOCIETA A RESPONSABILITA LIMITATA, OSTERREICHISCHE ENERGIEAGENTUR, TEMATYS

Contact: Vojislav.Petrovic@joanneum.at

JOANNEUM RESEARCH is an innovation and technology provider in the field of applied research and, as a research organisation of the federal states and regions, we shape the development of our modern society and economy in a sustainable and people-centred way with our research expertise.

As a multidisciplinary team in flexible, innovation-friendly structures, we live up to the highest social and scientific standards.