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ÉireComposites (Galway, Ireland), Plasma Bound (Dublin, Ireland) and Technological University Dublin (TU Dublin, Dublin, Ireland) have obtained funding for the Ad Astra project. The work will be supported under the Disruptive Technologies Innovation Fund (DTIF) Call 5, which is led by the government of Ireland and Enterprise Ireland.

Lightweight composite materials’ strength-to-weight ratio versus metal alloys provides reduced weight and increased fuel efficiency, but rapid, cost-effective bonding of these materials can be challenging. Effective surface preparation is a prerequisite for achieving a strong, durable bond, but current surface preparation techniques can be highly labor intensive, increasing process costs.

Plasma Bound has developed a surface treatment called controlled polymer ablation (CPA), which is applied prior to the bonding of lightweight composite materials. This automated and highly repeatable process, previously prototyped successfully by ÉireComposites, is designed to selectively remove the top layer of the polymer via plasma ablation with minimal thermal input and without damaging the fiber reinforcement of the composite material.

TU Dublin, the third partner of the team, brings its material testing and surface characterization capabilities to the consortium. These skills will be utilized to show that the CPA process results in higher forces prior to failure. When performing against traditionally prepared surfaces, the CPA technology is said to demonstrate improved repeatability, reliability and sustainability.

The development of the plasma ablation process through the DTIF helps remove barriers and enables greater adoption of lightweight materials in multiple areas of the manufacturing process for the aerospace industry. In addition, it intends to generate further economic growth in all regions of Ireland and create high-quality jobs for skilled people who live and work in rural Ireland.