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ÉireComposites (Galway, Ireland) announces its participation in the TOSCA (Technologies for Optimized Sustainable Composite Aerostructures) project, led by Profactor GmbH (Steyr-Gleink, Austria) in the quest to address persisting recycling and manufacture of carbon and glass fiber composites used in aerospace. TOSCA’s expectations are to tackle these economic and technical hurdles associated with composite materials through advanced manufacturing processes and digital tools by 2027.

Backed by €3.5 million from the European Union’s Horizon Europe Program, TOSCA brings together eight European partners — Profactor (coordinator),  ÉireComposites, Cidetec (Spain), GMI Aero (France), FIDAMC (Spain), Aimen Technologies Center (Spain), Technological Institute of Aragon (ITA, Spain) and Addcomposites (Finland) — over a 36-month period.

ÉireComposites bring its specialization in design, manufacturing and testing fiber-reinforced composite materials to the project.

TOSCA’s key objectives include:

1. Epoxy vitrimer resins
   • Advanced Manufacturing: Establish cost-effective, out-of-autoclave processing methods for vitrimer resins that offer enhanced repairability and recyclability while retaining the strength of traditional thermoset resins.
2. Inspection systems and health monitoring
   • Automation: Implement automated documentation for parts throughout their lifecycle.
   • Integration: Develop systems that feed data into digital structures, facilitating comprehensive part digitalization.
3. Innovative processes
   • Advanced Techniques: Focus on automated fiber placement, welding, repair and rework processes tailored to new materials.
   • Digital Integration: Incorporate inspection data to achieve zero-defect manufacturing.

By advancing these areas, TOSCA aims to reduce CO_â‚‚ emissions, manufacturing waste and noise pollution in aviation. The increased adoption of carbon fiber composites is expected to lower aircraft fuel consumption, while novel resins will enable the repair, reuse and recycling of components. These efforts align with the industry’s goal of a 30% reduction in fuel burn and CO_â‚‚ emissions by 2035.