RESTORE project

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

Start date : 1st January 2024
Duration : 48 months

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

Project presentation

RESTORE will offer sustainable by design remanufacturing process and materials along with supporting tools for digitalization of remanufacturing ecosystem or value chain. RESTORE is aiming to advance potential SoA cladding technologies including laser direct energy deposition (L-DED), plasma transfer arc (PTA) process for sustainable remanufacturing application. To increase the deposition rate for large scale applications, we are aiming to develop a novel hybrid process combining laser and PTA process. We are aiming to manufacture wire feedstock with recycled content and develop a wire feeding system coupled with secondary feeding system to transfer machining swarf/unused powder directly into the melt pool. We have already achieved the desired cladding performance by using 100% recycled content, therefore, its implementation in real world application will pave the way to zero waste and low-cost remanufacturing technology.

Apart from sustainable process and material development, to contribute to the digitalization effort, we are also aiming to develop RESTORE platform, which will offer digital technologies and tools, which are digital technologies to increase process automation, recipe book and simulation tools for product and process optimisation, decision support framework, ecoDESIGN framework, blockchain enabled digital product passport (DPP) framework, digital marketplace, business model templates, and collaborative spaces that can help to facilitate and streamline the remanufacturing process, providing greater traceability, transparency, and efficiency

Technical and economic impacts

• Deposition rate target ≈ 10kg/h for hybrid process
• Target allowable recycled content in the consumables ≈ up to 50%for wire feedstock
• Remanufactured industrial product and component qualified and certified
• Tool path optimisation – excessive metal deposited >5% of total deposited volume
• Performance of remanufactured component 100% matching of the virgin component

Project partners

• 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

Industrial context

The manufacturing industry faces increasing pressure to adopt sustainable practices to reduce waste, conserve resources, and minimize greenhouse gas emissions. Remanufacturing emerges as a pivotal solution, extending product lifespans, cutting production costs, and fostering circular economy principles. Despite its potential, remanufacturing remains underutilized due to technical, regulatory, and economic challenges, particularly in high-value industries like automotive, aerospace, and industrial machinery. RESTORE addresses these challenges through advanced technologies and digital innovations, paving the way for more sustainable and efficient industrial processes.

Key innovations

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

2. Process Innovation:
– Integrate digital solutions for autonomous damage detection and process control
– Low-waste, automated processes for high-value components.
– Multi-physics simulations to optimize component restoration processes

3. Business Model Innovation:
– Reshaping the value chain to integrate remanufacturing
– Raising customer awareness to encourage changes in consumption habits

Industrial applications

RESTORE’s solutions are designed for large-scale industrial components across naval, railway, automotive, and aerospace sectors. Examples include the remanufacturing of ship propellers, train bogies, and engine housings, where precision and durability are critical. Automated inspection, defect detection, and repair processes ensure these large components are efficiently restored to optimal performance. By reducing waste and extending product lifespans, RESTORE addresses sustainability goals while overcoming technical and regulatory barriers for widespread adoption, enabling these industries to embrace innovative, circular manufacturing solutions.