Objectives

The Project MIMOSA

Objectives

The MIMOSA Project's goal is to create multi-material joint structures using innovative concepts that can take advantage of digital and hybrid processes to generate superior technological and financial outcomes than the existing traditional joints.
Additionally, MIMOSA will pioneer the incorporation of recycling from the product and business ideation stage forward, paving the way for the circularity of materials and manufacturing. Using novel technology and a competitive technique for multi-material joints between AlSi10Mg alloy for additive manufacturing (AM) and composites (CFRP, carbon fiber-reinforced polymers), these goals and related needs will be met. The project suggests a new concept design for the joint, the regeneration of after-service materials, a reduction in weight (-51%), a reduction in lead time (-65%), and a reduction in the process' total environmental footprint.
  • OB1. Design of innovative AM-CFRP joints supported by multi-physical modeling and simulation
    The innovative design of AM-CFRP joint is optimised through FEM (finite elements method) models in the structural and thermo-structural domains. The preliminary model of an aerostructure prototype (vertical stabilizer), which will become the project demonstrator, is provided. The target KPIs are -51% joint weight, operational performances increase in terms of mechanical strength (vs. riveted joints and vs. adhesive-bonded joints).
  • OB2. Optimization and application of LB-PBF process for AlSi10Mg alloy
    Setup and optimization of the LB-PBF (laser beam powder bed fusion) AM (additive manufacturing) process for AlSi10Mg. Target density = 99.95%, yield stress = 215 MPa, Young’s module = 75 GPa. Application of the process to fabrication of samples and prototype metal components.
  • OB3. Optimization and application of APPD coating to metals
    Setup and optimization of the APPD (atmospheric pressure plasma deposition) coating with the goals of improving the metal-polymer adhesion and inhibiting the galvanic corrosion. Development of a preliminary numerical model of the plasma spray deposition for the joint metal surface. Application of the coating process to the metal samples and metal inserts of the prototype.
  • OB4. Fabrication of the joint with CFRP autoclave curing and fabrication of the prototype
    Completion of the joint fabrication through the CFRP (carbon fiber-reinforced polymers) autoclave curing process, with modified setup including metal inserts application. High quality, reproducibility and properties uniformity of the multi-material joint will be achieved through the processes optimization. Fabrication of CFRP samples, joint samples and fabrication completion of the vertical stabilizer prototype as business case.
  • OB5. Pre-standardization and establishment of safety levels for regulation and certification
    Definition of the best practice guidelines needed to align MIMOSA materials, components and processes to the normative prescriptions. These include the respect of technical requirements, the definition of safety levels and of testing certification procedures at the levels of materials, components and processes.
  • OB6. After-service recycling of materials with the creation of technological and economic value
    Setup and optimization of IGA (inert gas atomization) process for metals recycling and mechanical processing for CFRP recycling. Providing effective economic value to after-service materials, as a part of the exploitation business model by producing new metal powder with verified quality for the AM industry and thermoplastic fillers for the polymer industry with standard properties. The environmental impact is reduced by elimination of health hazards/pollution of metal chromate paints. The Project applies the concept of design for recycling to achieve the OB6.
  • OB7. Validation of KPIs of samples and prototype (vertical stabilizer) by testing campaign
    Execution of fatigue tests on LB-PBF metal samples, static/fatigue tests on CFRP samples, static/fatigue tests on joint sample, tests on the prototype of vertical stabilizer.
  • OB8. Development of business plan for Project’s exploitation; economic validation through the prototype
    Improvement of global process performances with target KPIs: lead-time, overall energy efficiency and costs (price retaining) due to optimization of assembling, transportations and other improvements. Development of business model and strategy, for the commercial exploitation after the Project, even addressed to different markets than aeronautics, with expected revenue streams, costs and customer segments. Validation of the business model on the prototype (business case) according to the preliminary estimations.