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12.25 | End of year Insights & Progress

TOOL4LIFE is a project that aims to impact on the sustainability in the composite sectors. Nowadays more than 95% of this market uses non-recyclable materials landfilled after their use.

TOOL4LIFE project aims to address the issues of sustainability in a fundamental pre-processing step for the composite manufacturing, designing and manufacturing tooling in thermoplastic materials with hybrid AM technology. The new process will reduce the raw material, energy consumption and consequentially the related CO2 equivalent emissions.

RESULTS AND ACHIEVEMENTS

The TOOL4LIFE project is entering its final phase, with only a few months left before completion. The system is now undergoing industrial validation, and the results achieved so far are extremely promising. After three years of development, testing, and iterative optimization, the project is demonstrating that a true transition toward more sustainable composite tooling is not only possible but can be faster, cleaner, and fully compatible with industrial performance requirements. The Life Cycle Assessment (LCA) confirms a significant reduction of environmental impact. Switching from conventional tooling to the TOOL4LIFE solution reduces climate-changing emissions from 6 to 0.96 tonnes of CO₂eq per tool (–84%). In subsequent production cycles, thanks to the recovery and reuse of thermoplastic material, the reduction reaches –97%. These results confirm that replacing non-recyclable thermoset tooling with fully recyclable thermoplastic tooling enables measurable environmental benefits, shorter lead times, lower waste-management costs, and increased circularity across the entire manufacturing chain. By combining large-scale additive manufacturing, FEM-based material optimization, and water-based sustainable coatings, TOOL4LIFE is proving that high-performance tooling can coexist with industrial sustainability goals.

Make sure to follow us at the upcoming events to learn more about our final achievements and how TOOL4LIFE technologies can support the transition to a circular composites industry.

LATEST EVENTS

TOOL4LIFE final workshop at JEC Forum Italy 2025

On June 11th, TOOL4LIFE was presented by Bercella during the conference. Later that day, the project held its third and final workshop, organised jointly with its sister project ZeroWasteLIFE as part of the JEC Forum Italy. The event, co-organised by JEC and Assocompositi, brought together more than 400 participants from across the composite industry. Speakers from Bercella and RINA showcased how both projects are redefining tooling and component manufacturing through innovation and circularity, demonstrating that it is now possible to dramatically reduce emissions, waste, and energy consumption while maintaining full industrial performance.

The full presentation and workshop recording is available on:

https://www.jeccomposites.tv/jec-forum-italy/

You can also find the workshop e-proceedings at:

Day-1_1430-Bercella_Tool4Life-ZeroWasteLIfe_workshop_JEC_forum_11-06-2025.pdf

TOOL4LIFE at EUIndTech 2025

TOOL4LIFE was featured at EUIndTech 2025 in Krakow, one of the European Commission’s flagship events on advanced manufacturing, with more than 800 attendees from industry, research, and policymaking. The project was showcased in the poster session and at the RINA booth, attracting strong interest thanks to its ability to reduce material waste.

An abstract about TOOL4LIFE has been published in the book of abstracts: https://www.indtech2025.eu/wp-content/uploads/2025/10/Innovative-Ideas-of-Young-Scientists-Science-Start-up-Industry-1.pdf

TOOL4LIFE at INFOHappening Melt Processing Technologies

TOOL4LIFE was also featured at the INFOHappening hosted by Centexbel in Kortrijk, where the project was present alongside a physical demonstrator showcasing its thermoplastic tooling concept. The event offered participants the opportunity to explore advanced melt-processing research and material processing innovations.

Figure 1- TOOL4LIFE final workshop at JEC Italy

Figure 2- TOOL4LIFE in the poster session at EUIndTech

TOOL4LIFE at METSTRADE 2025

Bercella was present the TOOL4LIFE innovations at METSTRADE, the world’s most important trade fair for marine equipment, materials, and advanced technologies. From 18 to 20 November 2025, visitors had the opportunity to meet the project team at Booth 12.823 at the Amsterdam RAI exhibition centre. The project’s approach to circularity applicable in the nautical sector has been highlighted, presenting early results, materials, and technologies currently under development. This presence offered a valuable opportunity to engage with industry stakeholders and gather feedback.

TOOL4LIFE at the 3rd International Online Conference on Polymer Science

TOOL4LIFE was also be showcased in a scientific and technical context at one of the leading virtual conferences dedicated to polymer innovation, advanced design, and sustainability. RINA presented the talk “A sustainable path for composite tooling: novel materials, design, and technologies through FEM and LCA” on 21 November 2025. The presentation illustrated how TOOL4LIFE integrates: Novel recyclable thermoplastic formulations for composite tooling; FEM-based advanced design optimisation to minimise tool mass and material demand; Comprehensive sustainability assessment (LCA, LCC, and Social LCA) demonstrating both environmental and economic benefits.

The recording of the event will be soon available on the event website.

Figure 3 - TOOL4LIFE at METSTRADE 2025

Figure 4- TOOL4LIFE at IOCPS

We look forward to sharing our final results, stay updated:

🌍 www.tool4life.it

🔗 LinkedIn – @TOOL4LIFE Project

11.24 | Project Update

TOOL4LIFE is a project that aims to impact on the sustainability in the composite sectors. Nowadays more than 95% of this market uses non-recyclable materials landfilled after their use.

We are pleased to share the successful outcome of our recent in-person workshop, The Future of Advanced Polymers and Composites: Strategies for Improved Sustainability, held on September 24th at the Santa Elisabetta Center, University of Parma Campus, Italy. This event built on the groundwork laid during our first online workshop in 2023, marked a significant step forward for the TOOL4LIFE project in sharing project results and our mission. The workshop gathered stakeholders, industry experts, and project partners to explore the ongoing research and innovation in sustainable composites. Representatives from TOOL4LIFE and other European sustainability projects, such as ZeroWasteLIFE, LIFE CFCycle, LIFE CIRCE, DECOAT, CISUFLO, POLYNSPIRE, and REFRESH presented their advancements. Each session highlighted approaches to reducing waste, increasing recyclability, and optimizing resource efficiency. Several innovative projects, including FURHY, PLOOTO, TARPAULIFE, RARE2, and ECOFACT, were featured in a dedicated poster and pitch session, showcasing emerging technologies and industrial applications. On our website an extract of the event is published.

Furthermore, we are proud to have participated in the International Astronautical Congress (IAC) 2024, held in Milan from October 14 to 18, where TOOL4LIFE was showcased at Bercella’s stand. This prestigious event in the space industry brought together leading organizations, innovators, and stakeholders from around the world. TOOL4LIFE’s presence highlighted our innovative and sustainable solutions for advanced composites, underscoring our commitment to driving sustainability not only in aerospace but across various industries.

NEXT EVENTS

The TOOL4LIFE team is excited to announce its upcoming participation in prominent industry events that will showcase our project’s innovative solutions for sustainable composites. Come meet us and discover more about our work!

EXPO & CONVENTION – Formnext

Frankfurt, 19 – 22 November 2024

Bercella, with TOOL4LIFE project, will be present at Formnext Frankfurt, one of the most anticipated events in the Additive Manufacturing (AM) industry. Held from 19 – 22 November 2024 in Frankfurt am Main this international exhibition serves as a key platform for sharing advancements across the AM process chain. The event will feature a broad array of cutting-edge solutions and insights into the future of 3D printing and industrial sustainability.

4th International Conference "Circular Economy for Textiles and Plastics"

Ostend, 19 – 20 November 2024

TOOL4LIFE will also be featured in a poster presentation at the 4th International Conference on a Circular Economy for Textiles & Plastics, organized by Centexbel and Fedustria. This prestigious event will bring together 26 speakers and 9 poster presentations from Europe and the United States, providing a dynamic platform to foster discussions on innovative circular solutions for textiles and plastics.

greenSME Sustainability Insights: Product Life Cycles and Sustainable Manufacturing

Online, 27 November 2024

TOOL4LIFE will be presented by RINA-C at this online event organized by greenSME, held from 4:00 PM to 5:00 PM. The event will focus on product life cycles and sustainable manufacturing practices, offering a valuable opportunity to exchange insights and highlight TOOL4LIFE’s innovative contributions to the broader sustainability landscape.

01.24 | New Challenges and Sustainable Innovations

TOOL4LIFE is a project that aims to impact on the sustainability in the composite sectors. Nowadays more than 95% of this market uses non-recyclable materials landfilled after their use.

RESULTS AND ACHIEVEMENTS

Over the past eighteen months, the Consortium has dedicated itself to pursuing TOOL4LIFE's core objectives. Despite encountering challenges along the way, TOOL4LIFE has made significant advancements in developing its innovative system. The Demo plan has been successfully implemented at Bercella facilities, where efforts are currently underway to produce prototypes.
This phase aims to explore the system's full potential and establish optimal parameters for the imminent testing phase of TOOL4LIFE. Progress on the selection of the polymer has reached an advanced stage, yielding promising results.

The current focus is on assessing their maximum recyclability and developing a more sustainable coating. Modeling activities have shown encouraging outcomes in optimizing mass reduction, and the initial sustainability assessment paints an optimistic picture of the final project results.

EVENTS

We are delighted to share noteworthy highlights from the recent International Business Convention for composite Materials event, where our project coordinator, Bercella, showed TOOL4LIFE achievements among more than 200 experts.

This gathering, held on November 15 & 16, 2023, at La Cité des Congrès de Nantes, France, brought together participants who are leading authorities in the field of composite materials. The Composite Meetings Business Convention, organized by the EMC2 competitiveness cluster and abe-advanced business events, provided a dynamic platform for international users and suppliers of Composite Materials.

The event facilitated 40-minute qualified and pre-programmed meetings, fostering meaningful connections and collaborations within the industry. Beyond being a mere event, Composites Meeting stands as a strategic tool for professionals aiming to expand their networks and explore new avenues.

As we reflect on the ongoing dedication within TOOL4LIFE, we look forward to a future where innovation and sustainability harmonize, paving the way for a greener and more resilient composite materials industry. Thank you for being part of this journey towards positive changes.

08.23 | One year of Tool4Life

TOOL4LIFE is a project that aims to impact on the sustainability in the composite sectors. Nowadays more than 95% of this market uses non-recyclable materials landfilled after their use.

WHERE CAN YOU MEET TOOL4LIFE?

On 26th September TOOL4LIFE partners will organize a free workshop online “Improving Sustainability in the Manufacturing Sector”, where it will be possible to know more about the project and the latest outcomes. The event foresees the presentation of other research and development projects working on the sustainability in different manufacturing sector. This will be a good opportunity to learn more about innovative solutions and exchange knowledge between manufacturing professionals.

Don’t miss it out! Registration link: https://t.co/6lCQv56fYO

On 17th October TOOL4LIFE partners will participate to a breakfast session organized by CENTEXBEL “3D-printing of waste materials”. The participation will be possible in presence or online, several presentations related to 3D-printing of recycled content are foreseen.

More details here: https://www.centexbel.be/en/agenda/breakfast-session-3d-printing-waste-materials

10.22 | The Composites of tomorrow

Composite materials find their greatest potential in applications where weight reduction is required without compromising rigidity and resistance of the material. Despite the high performance of these materials, their sustainability is still a major concern.

Tooling market is composed of about 70% of Polyurethanes (PU), 25% of Epoxies, and the remaining of other foamed or solid polymer components (Grand View Research, 2020). According to these values, more than 95% of the market is inherently non-recyclable, being composed of thermosetting materials typically landfilled after their function is over.
Furthermore, the originating chemistry relies on components that pose serious health issues (isocyanates, epichlorohydrin – ECH, bisphenol A – BPA).

Against these problems and great limitations, the TOOL4LIFE project was conceived, with the target of addressing the issues of sustainability in a fundamental pre-processing step for the composite manufacturing, substantially contributing to the global sustainability. TOOL4LIFE aims to design and manufacture tooling in thermoplastic materials with hybrid technology (AM followed by milling and in-mould coating).
During the project new water-based formulations for in-mould sealant, demoulding and finishing agents will be developed in order to reach a fully retrofittable solution. The process will enable the use of 20% to 25% polymer material reducing up to the 80% the volume of material used, 33% less energy and emits only the 9,2% of the CO2 equivalent against the current benchmark.

The developed tooling will be completely recyclable after use.

Officially started on 1st August 2022, TOOL4LIFE is a 3-years project coordinated by BERCELLA Srl, an Italian composite manufacturer, and involves three other partners: RINA CONSULTING SpA (Italy), CENTRE SCIENTIFIQUE & TECHNIQUE DEL’INDUSTRIE TEXTILE BELGE ASBL (Belgium), MARBO ITALIA Srl (Italy).

LIFE is 30!

The LIFE programme 2021-2027 is the only EU funding programme entirely dedicated to environmental, climate and energy objectives. It contributes to the shift towards a clean, circular, energy efficient, climate-neutral and climate-resilient economy, including through the transition to clean energy, to protect and improve the quality of the environment. To date, LIFE has co-financed more than 5,000 projects.

In terms of specific objectives, the programme seeks to develop, demonstrate and promote innovative techniques, methods and approaches to reach EU environmental and climate goals. It also supports the development, implementation, monitoring and enforcement of relevant Union legislation and policy, including by improving governance at all levels. Moreover, the programme aims to act as a catalyst for the large-scale deployment of successful technical and policy-related solutions by integrating related objectives into other policies and into public and private sector practices, by mobilising investment and by improving access to finance.

Tool4Life enters this landscape aiming to improve sustainability in composites manufacturing, among others.

Lines of exploitation

1st line - Y1 to Y3

Internal Composites capacity;
1 to 1,5 M€ Forecast advantages combining Turnover increase and reduced costs;
Visibility through Project Dissemination channels.

2nd line - Y4 and Y5

Active engagement of Composite manufactures to become customers of Bercella tooling.

>3 M€ Forecast Turnover increase & reduced costs;
1 M€ Forecast Turnover from supply of toolings;
Word-of-mouth and continuous visibility.

3rd line - beyond Y5

Widest Market Access;
Multiplication through Licensing and Third Party;
>10 M€ Forecast Turnover increase, reduced costs and tooling sales;
>4 M€ Forecast Turnover from Licenses;
Visibility through Global access Knowledge and market channels.

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