GreenFLY
About the *project.*
The GreenFLY project addresses recycling challenges in thermosetting composites with innovative solutions, aligning with the European Union's 2050 sustainability and CO2 reduction goals.
It aims to develop an innovative solution for manufacturing thermoplastic-matrix composites. It focuses on sustainability, energy efficiency, recyclability, and industrial scalability. The project addresses barriers to the use of these materials across sectors such as automotive, aerospace, and medicine. These sectors require high-performance, lightweight structures and strength.
It also tackles recycling challenges by reusing non-conforming parts through advanced processing technologies. This approach reduces production costs and environmental impact.
The project runs from February 2025 to July 2026, with a total budget of around €1.800.000 and the participation of a consortium of 6 organizations, divided into Business and Non-Business Entities in the R&D System.
Key *objectives.*
Pilot Unit for Thermoplastic Composite Production
Design and build a modular pilot unit for the automated, large-scale production of thermoplastic composite materials (organosheets), integrating all process steps into a single, fully automated line to deliver mechanically strong, fully recyclable components.
Integration of Biodegradable Materials
Incorporate natural and biodegradable fibers, such as flax, bamboo, and sisal, into composite materials to create fully recyclable solutions with reduced environmental impact, while meeting current market mechanical and performance requirements.
Production Efficiency and CO₂ Reduction
Develop a more sustainable processing system using induction heating and a rotating mold tool that combines thermoforming of prepregs with polymer over-injection, allowing for quick heating and cooling cycles to reduce energy consumption and emissions.
Production Cost Reduction
Reduce production costs by about 10% compared to emerging competing technologies through cycle-time reduction, utilizing a bi-material mold concept combined with rapid heating and cooling techniques to streamline fiber forming and improve energy efficiency.
Expansion Into New Application Sectors
Identify and develop new application areas for bio-based, sustainable composites in the automotive, aerospace, and medical sectors, leveraging advanced processing technologies developed throughout the project.
Beyond Vision's *role*.
We will define a practical case study for this project, introducing these materials to product development within the industries we operate in. We hope that this practical use will serve as proof of concept for the technical and commercial viability of the solutions.
The versatility of biodegradable thermoplastic resins across different reinforced composites enables broad applicability, encouraging a ripple effect as other industries adopt and customize the system to suit their specific requirements.