Manufacture of bio-composites prototypes

Grant Agreement number: 101058371 Project acronym: ESTELLA Project title: Design of biobased thermoset polymer with recycling capability by dynamic bonds for bio-composite manufacturing Grant Agreement number: 101058371 Project acronym: ESTELLA Project title: Design of biobased thermoset polymer with recycling capability by dynamic bonds for biocomposite manufacturing DELIVERABLE 3.3 Manufacture of biocomposites protypes Contractual Date of Delivery: 31-05-2025 Actual Date of Delivery: 27-06-2025 Lead contractor for this deliverable: FUNDACIÓN CIDAUT Author(s): CID Participants(s): CID WP contributing to the deliverable: WP 3 Nature: SEN Version V. 2 Grant Agreement 101058371 Project ESTELLA Deliverable T3.3 ©ESTELLA - This is the property of ESTELLA Parties: shall not be distributed/reproduced without formal approval of ESTELLA General Assembly. therein. Executive Summary This deliverable describes the approach for the manufacturing of both composite prototypes as it was seen in Tasks 2.4 and 3.2, and related to the recyclability assessment in WP4 and composites selected in Task 3.1. The work carried out in this task focuses on the definition, simulation, and validation of the out-of-autoclave (OOA) manufacturing process using the final composites. The initial simulation-based methodology of the process has been used the same from Task 3.2, with some improvements made to incorporate the material characterization and tooling developments. Key activities and outcomes: Experimental validation: The simulated parameters were validated experimentally to confirm process feasibility and reproducibility using the selected OOA process. Mould tool manufacturing: Based on the tool designs developed in Task 3.2, moulds for both composites were fabricated. Test specimen manufacturing: Flat test specimens were manufactured from the prototypes obtained with the validated OOA process. These specimens were tested to evaluate the decrease of mechanical properties over time after immersion in water in Task 3.4. Prototype manufacturing: The final composite prototypes were manufactured using the conventional out of autoclave process. In parallel, predictive models were developed using the information from the materials characterization. These final composites were used also for studying the recyclability process of the WP4. In this deliverable it was corroborate the simulation with the experimental manufacture of the prototypes including the design of the process, moulds and prototypes manufactured.