ProjectRESTORE

“Sustainable Remanufacturing solution with increased automation and recycled content in laser and plasma-based process”

Start date: 1 January 2024
Duration: 48 months

The RESTORE project has received funding from the European Union’s Horizon Europe programme under grant agreement No. 101138775.

RESTORE will propose sustainable-by-design remanufacturing processes and materials, together with support tools for the digitalisation of the remanufacturing ecosystem or value chain. RESTORE aims to advance promising state-of-the-art (SoA) coating technologies, notably laser directed energy deposition (L-DED) and the plasma transferred arc (PTA) process, for sustainable remanufacturing applications. To increase the deposition rate for large-scale applications, we aim to develop a new hybrid process combining the laser process and the PTA process. We aim to manufacture a wire feedstock with recycled content and to develop a wire feeding system coupled with a secondary feeding system to transfer machining chips/unused powder directly into the melt pool. We have already achieved the desired coating performance using 100% recycled content. Its implementation in real-world applications will therefore pave the way for a zero-waste, low-cost reconditioning technology.

In addition to the sustainable development of processes and materials, and to contribute to the digitalisation effort, we also aim to develop the RESTORE platform, which will offer digital technologies and tools: digital technologies to increase process automation, a good practice handbook and simulation tools for products and processes, optimisation, a decision-support framework, an ecoDESIGN framework, a blockchain-enabled digital product passport (DPP) framework, a digital marketplace, business model templates and collaborative spaces that can help facilitate and streamline the remanufacturing process, providing greater traceability, transparency and efficiency.

• Target deposition rate ≈ 10kg/h for the hybrid process
• Target permitted recycled content in consumables ≈ up to 50 % for wire feedstock
• Qualified and certified reconditioned industrial products and components
• Tool path optimisation – excess metal deposition > 5 % of total deposited volume
• Performance of the reconditioned component 100% matching that of the new component

• EUROPEAN FEDERATION FOR WELDING JOININGAND CUTTING
• IRIS SRL
• FRAUNHOFER GESELLSCHAFT ZUR FORDERUNGDER ANGEWANDTEN FORSCHUNG EV
• AKTIEBOLAGET DALFORSAN
• PARIDA CONSULTING AB
• NAVTEK DENIZ TEKNOLOJISI ANONIM SIRKETI
• WELDING ALLOYS FRANCE SAS
• INDUSTRIALISATION DES RECHERCHES SUR LESPROCEDES ET LES APPLICATIONS DU LASER
• GSMC
•  FLOWPHYS AS
•  AEROBASE INNOVATIONS AB
•  ENDURANCE SPA
•  CENTRO RICERCHE FIAT SCPA
• PHD CONTROLLED SOLUTIONS AB
• MSC SCANNING
• EIT Manufacturing North AB
• CRANFIELD UNIVERSITY
• INTELLEGENS LIMITED
• LUCCHINI UNIPART RAIL LIMITED
• TECHNOVATIVE SOLUTIONS LTD

The manufacturing industry is under increasing pressure to adopt sustainable practices aimed at reducing waste, conserving resources and minimising greenhouse gas emissions. Remanufacturing is emerging as a key solution, extending product life, reducing production costs and promoting the principles of the circular economy. Despite its potential, remanufacturing remains under-used owing to technical, regulatory and economic challenges, particularly in high-value-added sectors such as automotive, aerospace and industrial machinery. RESTORE tackles these challenges through advanced technologies and digital innovation, paving the way for more sustainable and efficient industrial processes.

1. Product innovation:
– Modular product designs for reuse, repair or recycling
– Digital passports for product traceability

2. Process innovation:
– Integrating digital solutions for autonomous damage detection and process control
– Automated, low-waste processes for high-value components.
– Multi-physics simulations to optimise component restoration processes

3. Business model innovation:
– Reshaping the value chain to integrate remanufacturing
– Raising customer awareness to encourage them to change their consumption habits

RESTORE solutions are designed for large-scale industrial components in the marine, rail, automotive and aerospace sectors. Examples include the reconditioning of ship propellers, train bogies and engine casings, where precision and durability are essential. Automated inspection, defect detection and repair processes ensure that these large components are efficiently restored to optimum performance. By reducing waste and extending product life, RESTORE meets sustainable development goals while overcoming technical and regulatory barriers to widespread adoption, enabling these industries to embrace innovative, circular manufacturing solutions.

• Total budget : 8 840 000,00€
• Total budget for IREPA LASER : 498 250€
• Funding from the European Union’s Horizon Europe programme : 498 250€

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• Visit the LinkedIn page
• View the RESTORE project poster