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.

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.

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

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). 

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.

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.