Objectives

Results

Bio-Uptake

BIOcomposites in smart plastic transformation processes to pave the way for the large-scale UPTAKE of sustainable bio-based products

Objectives

The general objective of Bio-Uptake project is to ensure a sustainable uptake (increase the use in a 39%) of bioplastic composites through boosting a twin green and digital transformation in the European manufacturing industry. Bio-Uptake solution will focus scientific and technology efforts on developing flexible manufacturing processes to produce biobased end-products for the construction, medical and packaging sectors based on the combination of intermediate formats made of natural and/or biobased synthetic fibers reinforced with biopolymers, which are easily adaptable to new market demands.

To do so, project beneficiaries will pursue the following Specific Objectives (SO)

S01
To develop 3 disruptive innovative manufacturing processes for bio-based products with a better overall performance of the current fossil-based alternatives

One for thermoset composites, one for highly customized thermoplastics and one for one-shot large volume thermoplastics.

S02
To adapt and upgrade 6 conformal manufacturing technologies

Filament extrusion, extrusion-compounding, resin impregnation, press consolidation, thermoforming and over-injection, that constitutes the manufacturing processes for deploying biobased materials to substitute traditional materials.

S03
To implement a smart digital end-to-end platform for manufacturing biobased materials

Design, modelling, process simulation, in-line monitoring and quality diagnosis, to ensure product quality and process interoperability required to optimize and upgrade each manufacturing process being demonstrated for each user case and its scalability to any other manufacturing process.

S04
To develop and validate 4 new biobased intermediate formats or semi-finished products
  • endured thermoset organosheets
  • monocomponent & bicomponent thermoplastic organosheets
  • unidirectional tapes
  • thermoplastic pellets or granulates.
S05
To demonstrate the Bio-Uptake solution in 3 manufacturing value chains (VC)
  • construction
  • medical
  • packaging
S06
To develop 3 end-products

Bathroom ceiling cabinet, feet orthosis and garbage container lid, that are made of more than 75% biobased materials and to validate the technical and environmental requirements.

S07
To demonstrate product circularity

Reusability, remanufacturability and/or recyclability, by validating their demanufacturing process (due to reversible dynamic chemicals (CANs) and aided by eco-design principles.

S08
To create 2 training programs

For upskilling professionals in circular economy and smart & green manufacturing practices: one for young generations of scientists & engineers and one for industrial workforce.

S09
To contribute to the standardization

Applied to the 3 manufacturing value chains driving biomaterials uptake.

Bio-Uptake

BIOcomposites in smart plastic transformation processes to pave the way for the large-scale UPTAKE of sustainable bio-based products

Main results

To answer all these objectives, you can see below all the tasks that will be implemented in the BIO-UPTAKE project.

[Done] [in progress] and [not started] will be used to track the progress of each action.

WP2 : Optimisation and manufacturing of intermediate bio-composite formats

T2.1 Extrusion of reinforced bio-based fibres [done]

We successfully produced high-strength PLA multifilament yarns, achieving a tenacity exceeding 50 cN/tex and a modulus greater than 9 GPa. In addition to these mechanical improvements, we significantly reduced the shrinkage of the yarn. Furthermore, matrix yarns of PLA and PCL were also developed for the biobased composites.

T2.2 Modelling and Synthesis of bio-based dynamic chemicals

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T2.3 Preforming of thermoplastic bio-sheets

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T2.4 Compounding of fibre reinforced bio-pellets

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T2.5 Production of thermoset bio-composites [done]

CIDETEC has successfully manufactured 210 linear meters of 3R bio-based prepreg rolls, marking a significant step forward in sustainable composite materials. These prepregs were created by impregnating flax fiber with an advanced 3R bio-based epoxy resin, formulated using Diglycidyl Ether of Vanillyl Alcohol (DGEVA), a renewable compound developed by SPECIFIC POLYMERS.

The result is a material that not only meets performance standards but also aligns with circular economy principles—fully recyclable and reprocessable, without compromising quality. This cutting-edge solution has been validated by PODCOMP, the end-user, for its reliability and sustainability and it is now set to be used in the manufacturing of a modular bathroom ceiling demonstrator, showcasing the potential of bio-based composites in real-world, high-performance applications.

T2.6 Development of in-line characterisation methods

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WP3 : Optimisation of the manufacturing processes for final bio-composite products

T3.1 Process modelling

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T3.2 Free-forming of orthopaedics

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T3.3 Over-injection of tertiary packaging

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T3.4 Thermoforming of bath ceilings

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T3.5 Fast quality control measures of the final products

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T3.6 FEnvironmental and Human safety characterisation

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WP4 : Digital systems and Interoperability

T4.1 Interoperable embedded platform

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T4.2 Data analytics for adaptive manufacturing systems

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T4.3 Data analytics for product design

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T4.4 Hybrid-digital twin

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WP5 : Demonstrate innovative bio-based material production and bio-based products

T5.1 Smart systems integration

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T5.2 Pilot line optimisation and testing

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T5.3 Validation of user cases in the medical, packaging and construction value chains

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T5.4 Sustainable end-of-life models for new circular and regenerated products

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