Project VITAL: Innovative processing technologies for bio-based foamed thermoplastics.

VITAL aims to generate fundamental knowledge and expertise to underpin future European activities to substitute existing synthetic thermoplastics with those from bio-based sources and in so doing, enable the European polymer processing sector to achieve a paradigm shift towards bio-based alternatives for cleaner, more climate neutral industrial value chains. 

This is achieved through the development of thermoplastic foaming processes, combined with smart digital control approaches, that will enable bio-based thermoplastics to be processed both on traditional processing equipment (for foam injection moulding and bead foaming) as well as developing a globally unique 3D printing approach for foamed thermoplastics. These processing technologies represent three ‘valuechains’. 

In addition, bio-based thermoplastic mechanical recycling developments aim to underpin progression of engineering applications towards a ‘Circularity by Design’ approach. The knowledge produced is widely disseminated through various conduits, including a Learning Factory that aims to give access to pilot scale industrial lines for each of the 3 value chains to reduce the risk for industry for adoption of the technologies. 

VITAL brings together a world-leading consortium consisting of industrial processors andequipment manufacturers along with end-user partners from the automotive, electronics and marine sectors and leading research and technologies organizations from across Europe. The six use cases in VITAL combine to address the expected outcomes and create pathways to mitigate ~75.000 tones CO₂ eq/year from fossil-based materials through a conversion to bio-based materials. The consortium along with the Advisory board provides a multiplier effect to broaden these impacts with further applications and uses. VITAL’s disruptive approaches aims to help industrial adoption by addressing the cost-challenges of bio-based materials by optimizing processing and material use.

Our main tasks

• Smart processing of foam injection moulding 
• Characterization: Mechanical, physical, and chemical properties
• Recyclability, refurbishment and remanufacture approaches
• Life cycle analysis
• Techno-economic analysis
• Social impact analysis
• Exploitation of results, including business model
• VITAL learning factory and training development
• Tech-futures analysis
• Open science & research data management

Partners

ARCELIK | AVIENT | BRITER | CENTRO RICERCHE FIAT | FARPLAS | FLOREON | FRAUNHOFER | ICONIQ | INNOVATION | IDENER.AI | MEYER TURKU | MEYER WERFT | PIEP | TOFAS | VTT

Start date – finish date

05 / 2022 - 04 / 2025