Europe’s railway industries require a step change in technologies and design for the next generation of rail vehicles in order to remain competitive globally. Innovative materials and modular design for rolling stock are considered to become key to success. Composite materials with their unique properties (lightness, repairabillity, corrosion resistance…) have demonstrated a high potential for lighter, more energy- and cost-efficient structural components in relevant sectors such aeronautic or automotive industries. However, currently available structural composites do not meet Fire, Smoke & Toxicity requirements of the railway sector, and thus cannot be used for the manufacturing of carbodyshell parts. Mat4Rail will face these challenges through a two-tier approach: In work stream I, our materials team (including resin producers, composite manufacturers, and experts on joining technologies and testing) will: i) synthesize novel fire retardant resins (epoxy, benzoxazine or hybrids) and manufacture composite batches; ii) modify fatigue and static load cases according to new requirements for polymeric materials; iii) further develop structural adhesive bonding combined with riveting and bolting for permanent and non-permanent joints and the repair of the new composites; and iV) assess novel design concepts for access door systems using new materials and joining technologies. In work stream II, our specialised design and engineering teams will develop new concepts for interior design of rolling stock including: i) plug and play systems which function like a limbic technical and power system for new electric utilities; ii) innovative lightweight seats and iii) a compact and ergonomic driver’s desk. Together, our multi-disciplinary consortium of 7 SMEs, 3 large industries, 5 RTDs and 1 UNI clearly has the experience and skills required to deliver innovations for uptake by the Shift2Rail JU members and the European railway industries.

With strong growly rates of 13% in the aero sector, and demands predicted to be doubled by 2032, carbon composites (CC) are under the spotlight. CC production requires a quick ramp-up that needs to be based on robust materials & processes and a solid manufacturing supply chain, where higher production rates and cost reduction are essential. The aim of AIRPOXY is to reduce production & MRO costs of CC parts in aeronautics by introducing a new family of enhanced composites that preserve all the advantages of conventional thermosets, while showing new unprecedented features such as Re-processability, Reparability and Recyclability. This will be possible through further development & validation of a family of ground-breaking thermoset resins (recently invented/patented by CID) including dynamic bonds which enable such smart behaviour. Conversion of the technology from TRL3 to 5 will be achieved in AIRPOXY, through 2 representative demonstrators of aircraft panels. Thermoforming processes previously unthinkable for thermosets will reduce manufacturing cost of CC parts by35% vs autoclave, reducing processing times from hours to minutes. Faster/cheaper repair technologies, in combination with SHM, will reduce significantly MRO costs. Additionally, a novel welding process will reduce CC bonding costs by up to 50%. Such new features will foster competitiveness & sustainability in the European aeronautics sector. AIRPOXY relies on a multidisciplinary consortium of 11 partners from 6 countries; CID as resin inventor, key technology providers IVW (thermoforming & welding), EUT(RTM), COEX(SQRTM), UOI(SHM); AEF (process simulation software), aircraft components manufacturers (EIRE, IDEC, SON), standardization experts (UNE) & an aeroconsultancy (ART). They will be supported by a strong advisory board (AIRBUS, Leonardo, Huntsman, SGL and EREA). Maximum impact of AIRPOXY will be ensured through well-balanced dissemination, communication and exploitation activities.