EXHUME - Efficient X-sector use of HeterogeneoUs MatErials in Manufacturing

Composite materials represent the future landscape for many industries. The possibility of combining better mechanical strength and reduced weight make composites the material of choice in transportation allowing unique design and functionalities in combination with high fuel efficiency. However, the increased use of composites, automatically leads to waste, either end-of-life or manufacturing waste. It is estimated that in the EU by 2015 end of life composite waste will reach 251,000 tonnes and production waste will achieve 53,000 tonnes. The composites industry, (in particular carbon fibre) is under increasing pressure to provide viable recycling technology for their materials. This is the case because the European Commission has controlled landfill and incineration of these materials.

Through research and development of novel recycling and re-manufacture processes, this EXHUME project will provide a step-change in composites resource efficiency. These composite materials evoke difficult scientific and technical recycling challenges due to the mixed nature of their composition. The project will demonstrate to the waste industry, vital re-manufacturing science and chemical/process engineering. It will develop the first data sets and exemplars of mixed composite processing and associated resource footprints that can be used to drive the future of scrap re-use across industrial sectors.

This project is pioneering in that it:
i) Is the first cross-sector research-inspired use of heterogeneous scrap material in manufacture.
ii) Develops novel transformation technologies to process thermoset and thermoplastic composites.
iii) Develops a fundamental understanding of microstructure-property relationship in scrap material and in manufacturing process science.
iv) Provides vital support to companies to exploit the scrap re-manufacturing technology.
v) Evaluates the energy and resource efficiency of composite, re-processing, re-use and re-manufacture assessing the environmental impact and business case.

This project provides the first known case of resource efficiency based optimisation of manufacturing processes for transforming and reusing heterogeneous scarp materials. Clarifying the underlying and limiting scientific principles for re-manufacturing at this early stage will provide essential input to a roadmap for end of life options for composites. The main economic beneficiaries of this project are the manufacturers of composites structures, end users of composite structures, waste treatment companies (including the SMEs), and ICT companies involved in the computer-aided design and manufacture of composites structures. This project will also have environmental and social benefits through more efficient composites manufacturing processes in terms of energy and material usage, leading to reduced waste-related health hazards. Finally, the academic beneficiaries are the research communities working in the areas of composites manufacturing, materials science, engineering optimisation, resource modelling and waste treatment.

The vision of this research is to become internationally leading in technologies for separation of heterogeneous materials in manufacturing. Successful delivery of this project will: (i) give confidence to the manufacturers of composites to continue development of lightweight structures, (ii) solve long-term legacy issues of composites waste and address legislation - the whole composites industry could decline if these issues are not addressed, (iii) demonstrate to the waste industry that their current approaches lack vital manufacturing and chemical/process engineering, (iv) develop the first data sets and exemplars of heterogeneous composites processing and associated resource footprints that can be used to drive the future of scrap reuse, and (v) open up a new SME-driven manufacturing sector in scrap processing using resource efficiency as a competitive and environmental advantage. This research will deliver a transformative increase in scrap material reuse in composites industry and bring major environmental benefits to the UK. This research fits with and complements other major research activities in the area: (i) NISP (WRAP) focuses on 'quick fix' solutions for ready-to-use scrap, whereas this project goes beyond and focuses on materials characterisation and remanufacturing process optimisation. (ii) EPSRC Centre for Innovative Manufacturing in Industrial Sustainability focuses on systems level approaches, whereas this project focuses on materials science and manufacturing technology based bottom-up solutions. (iii) EPSRC Centre for Innovative Manufacturing in Additive Manufacturing, EPSRC Centre for Innovative Manufacturing in Composites and NCC focus on manufacturing from virgin material input, whereas this project focuses on reuse of composite materials. (iv) OEM initiatives focus on intra company opportunities, whereas this project undertakes a cross-sector investigation.