Green Engineering, Analysis, & Reskilling for Unbounded Production

The GEAR-UP proposal, is a comprehensive initiative to revolutionize the manufacturing sector through sustainable practices and advanced technologies.

The project's central objective is to develop digital tools and methodologies that address recycled materials variability. It covers stainless steel, aluminum alloys, and fiber-reinforced plastics for additive manufacturing (AM).

It employs simulation-driven approaches for optimizing various AM processes, including laser beam-directed energy deposition, metal laser beam powder bed fusion, and fiber-reinforced polymer material extrusion.GEAR-UP also emphasizes environmental conservation by using recycled materials in engineering design, significantly reducing virgin resources, energy consumption, and greenhouse gas emissions.

The project intends to overcome challenges associated with secondary materials, such as performance variability, through resilient design and life-cycle environmental impact assessment.Moreover, the proposal outlines ambitious objectives for enhancing sustainable product design using innovative simulation and modeling software.

It also implements the Digital Product Passport initiative and fosters human involvement in advancing circularity and sustainable technology adoption. This is done through training and global collaborative networks.

GEAR-UP's approach represents a paradigm shift in engineering design, focusing on the circular value chain and developing universally adaptable AM technologies resilient to material variability.

This endeavor is expected to directly impact the high-performance consumer products, green energy, & high-tech robotics markets.

The key outcomes are:Cost savings: 25 %Increased productivity: 20-50 %Extended fatigue life: 50-80 %Defects reduced: 50-80 %Material waste reduced: 25-30 %CO2 emissions reduced: 25-50 %Reduced quality failures: 70-90 %Reduced design time: 20-50 %Reduced component weight: 25-30%