G an Ag eemen numbe : 101058371
P ojec ac onym: ESTELLA
P ojec i le: Design o bio-
based he mose polyme
wi h ecycling capabili y by dynamic
bonds o bio-composi e manu ac u ing
G an Ag eemen numbe : 101058371
P ojec ac onym: ESTELLA
P ojec i le: Design o bio-
based he mose
polyme wi h ecycling capabili y by
dynamic bonds o bio-
composi e
manu ac u ing
DELIVERABLE 3.1
P o o ype Design
Con ac ual Da e o Deli e y: 31s Ma ch 2024
Ac ual Da e o Deli e y: 1s Ap il 2024
Lead con ac o o his deli e able: CIDAUT (CID)
Au ho (s) (CID):
Ad ian Ped osa Valbuena & Albe o Blanco Rod íguez
Pa icipan s(s):
Ma ía Gál ez Sánchez & Alicia Rod íguez (CID)
WP con ibu ing o he deli e able:
WP 3
Na u e: Public
Ve sion V04
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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REVISION TABLE
Documen e sion Da e Modi ied sec ions - De ails
V01 2024.02.02 Fi s d a
V02 2024.03.13 Second d a
V03 2024.03.22 A e Technical Re iew (SINTEF & WK+)
V04 2024.03.27 A e Quali y e iew (SINTEF & WK+)
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Table o Con en s
TABLE OF CONTENTS .................................................................................................................... 3
ABBREVIATIONS ........................................................................................................................... 4
EXECUTIVE SUMMARY .................................................................................................................. 5
1. INTRODUCTION .................................................................................................................... 6
2. DEMONSTRATOR DESIGNS .................................................................................................. 7
WINDOW PROFILE .................................................................................................................. 7
SCOOTER PLATFORMS .......................................................................................................... 11
2.2.1. S uc u al analysis. ............................................................................................. 13
3. CONCLUSIONS .................................................................................................................. 19
BIBLIOGRAPHY ........................................................................................................................... 20
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
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Abb e ia ions
E: Young Modulus
FEM: Fini e Elemen Me hod
Kg: Kilog ams
mm: Millime es
MPa: Megapascals
MSC: Ma c Men a So wa e
OOA: Ou -o -Au ocla e
RTM: Resin T ans e Moulding
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
This e lec s only he au ho ’s iews. The Communi y is no liable o any use ha may be made o he in o ma ion con ained he ein.
Execu i e Summa y
This deli e able desc ibes he design o a s uc u al componen o he
cons uc ion sec o (window p o ile) and an i em add essing he
leisu e/mobili y sec o (scoo e pla o m) by using ecyclable and
sus ainable bio-based composi e ma e ials de eloped in WP2 o he
ESTELLA p ojec . The conclusions acqui ed in WP1 ha e been conside ed
when he selec ion o bo h p o iles we e decided.
CID has o e seen he de ini ion o he p o o ype geome ies and hei
design. Some ad ice on he de ini ion o he geome ies was p o ided by
ECRT.
To de elop he window p o ile, he VEGA model om STRUGAL has been
conside ed. Wi h espec o he scoo e pla o m, wo models om XIAOMI
and CECOTEC a e e e ed; XIAOMI 4 GO ELECTRIC and CECOTEC
BONGO D30XL, espec i ely.
This deli e able D3.1 has ully me he objec i es as se ou in he G an
Ag eemen . No de ia ions ha e been ound in he deli e able o in he
p og ess o he p ojec in e ms o con en , ime, o impac s.
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
This e lec s only he au ho ’s iews. The Communi y is no liable o any use ha may be made o he in o ma ion con ained he ein.
1. In oduc ion
In he con ex o his p ojec , he design and manu ac u ing o wo
p o o ype demons a o , ep esen ing di e en indus ial sec o s, ha e
been s udied using ecyclable and sus ainable bio-based composi e
ma e ials. In his con ex , he conclusions acqui ed in WP1 (mo e
speci ically in Deli e able 1.3) ha e been aken in o accoun .
Addi ionally, an assessmen o hei mechanical equi emen s and se ice
condi ions was conduc ed.
The esins ha will be used o he manu ac u ing o he wo p o o ype
demons a o s p esen ed in his deli e able ha e been de eloped, and
hei echnical easibili y, sus ainabili y and manu ac u ing p ope ies a e
being assessed in WP2 o ESTELLA p ojec .
The i s p o o ype, a ge ing he cons uc ion sec o , will be made wi h a
esin ein o ced wi h na u al, discon inuous, and sho ib es, speci ically
lignocellulose nano ib es. This composi e enhances he mechanical
s abili y o he base ma e ial o he in ended use equi emen s.
Addi ionally, i exhibi s he mal p ope ies ha ma ches and/o imp o es
hose achie ed wi h adi ional ma e ials. I ensu es good dimensional
s abili y in he ace o empe a u e changes, p e en ing undesi ed
de o ma ions and ensu ing op imal pe o mance o e ime. Based on he
abo e, i has been decided o use his ma e ial o he manu ac u e o a
window p o ile.
In con as , he second p o o ype, in ended o he leisu e/mobili y sec o ,
will be manu ac u ed wi h esin ein o ced wi h con inuous na u al ib e,
speci ically hemp in he o m o ab ic. The p ope ies o he esin will
ensu e he cohesion and du abili y necessa y in he inal componen . Due
o he good bending p ope ies ha a ab ic-based composi e ma e ial
can exhibi and he ocus on he leisu e/mobili y sec o , i has been
decided o manu ac u e an elec ic scoo e pla o m.
Figu e 1 shows he p o o ypes o be manu ac u ed and he ma e ials o
be employed.
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Figu e 1: O e iew o he demons a o s o be designed and manu ac u ed in he
ESTELLA p ojec .
Bo h app oaches ep esen ailo ed solu ions o he needs and
equi emen s o each indus ial sec o . I suppo s he op imiza ion o
ma e ials and manu ac u ing p ocesses h ough ou -o -au ocla e (OOA)
echnologies o achie e inal p oduc s ha mee es ablished s anda ds o
quali y and pe o mance.
Recyclable and sus ainable ma e ials a e being de eloped using OOA
echnologies in ESTELLA P ojec . They educe he inal weigh o he
p oduc s while main aining mechanical p ope ies. This con ibu es o
en i onmen al imp o emen and cu s cos s by lowe ing manu ac u ing
expenses. Consequen ly, i enhances he compe i i eness o companies.
This deli e able is an o e iew o he design p ocess ha has been
unde aken o he de elopmen o bo h p o o ypes.
2. Demons a o designs
Window p o ile
The window p o ile design was made conside ing echnical, geome ic,
and manu ac u ing aspec s. In he p o ile design, he comme cial VEGA
model om STRUGAL [1] (Figu e 2) was used as a e e ence.
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Figu e 2: S anda d window p o ile, he VEGA model om STRUGAL [1].
The window p o ile consis s o wo componen s: he ixed and mobile
pa s, which bo h ha e been designed. The p o ile hickness is 2.5mm, and
i s dimensions ha e been de e mined based on he UNE-EN 12608-1:2016
s anda d [2].
Today, pul usion echnology [3-4] is usually used o manu ac u e
composi e p o iles whe e con inuous ib es a e used as ein o cemen .
Howe e , in case o he ESTELLA P ojec , a esin cas ing p ocess [5] will be
used o he ollowing easons:
This manu ac u ing p ocess is used o manu ac u e he mose pa s
ein o ced wi h nanopa icles.
A small quan i y o p o iles wi h educed leng h will be p oduced.
I is a mo e economical manu ac u ing p ocess han he pul usion
p ocess.
The pul usion p ocess is usually ca ied ou only in cases whe e he e
is con inuous ein o cemen .
Based on hese conside a ions, he cas ing p ocess has been selec ed o
p oduce he bio-based nanocomposi e pa s. Howe e , his echnique
can be eplaced once es s ha e been done by a plas ic injec ion
moulding p ocess i equi ed by he p o ile cha ac e is ics.
The design o wo di e en pa s in e ms o geome y and complexi y has
been ca ied ou . As indica ed abo e, he STRUGAL model is used as a
e e ence o he design o bo h pa s o he window p o ile. The designed
ixed and mo able pa s a e shown in Figu e 3.
The cas ing p ocess has some geome ical limi a ions and he op ion o
modi ying o simpli ying he geome y will be conside ed i p oblems a e
encoun e ed du ing he manu ac u ing p ocess.
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Figu e 3: Designed window p o ile (a) ixed pa , (b) mo able pa , and (c) bo h window
pa s.
In he u u e deli e able 3.3, he manu ac u ing o one pa o he
designed window p o ile shown in Figu e 3 (a o b) will be ca ied ou .
To de e mine he echnical easibili y o he esin cas ing p ocess and he
quali y o he inal pa , p elimina y es s will be ca ied ou in which he
selec ed designs will be simpli ied by manu ac u ing a p o ile wi h
ec angula geome y. The simpli ied p o ile is shown in Figu e 4.
Figu e 4: Simpli ied ec angula window p o ile design.
This simpli ied design will enable he iden i ica ion o limi a ions o
conside a ions ha need o be conside ed du ing he manu ac u ing o
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Figu e 8: Fla geome y displacemen g aphs.
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
0 100 200 300 400 500 600 700 800 900 1000 1100
BENDING [MM]
LENGHT [MM]
CENTRE LINE BENDING
FLAT GEOMETRY-100Kg-Thickness 4mm-E2890 FLAT GEOMETRY-100Kg-Thickness 5mm-E2890
FLAT GEOMETRY-100Kg-Thickness 4mm-E8000 FLAT GEOMETRY-100Kg-Thickness 5mm-E8000
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Figu e 9: Cu e Geome y displacemen g aphs.
Quan i a i ely, all he analysed cases ha e been compiled in Table 4. As
seen o he la pla o m, he highes maximum displacemen (9.54 mm
maximum de lec ion, ep esen ing 100% de o ma ion) was achie ed wi h
he smalles hickness and he lowes ma e ial s i ness. In con as , o he
cu ed model, he maximum displacemen o he cu ed pla o m wi h
he g ea es hickness and highes ma e ial s i ness is conside ably lowe ,
eaching a de o ma ion o 1,57 mm, 83% less han he pla o m wi h he
highes displacemen .
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
0 100 200 300 400 500 600 700 800 900 1000 1100
BENDING [MM]
LENGHT [MM]
CENTRE LINE BENDING
CURVE GEOMETRY-100Kg-Thickness 4mm-E2890 CURVE GEOMETRY-100Kg-Thickness 5mm-E2890
CURVE GEOMETRY-100Kg-Thickness 4mm-E8000 CURVE GEOMETRY-100Kg-Thickness 5mm-E8000
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
This e lec s only he au ho ’s iews. The Communi y is no liable o any use ha may be made o he in o ma ion con ained he ein.
Table 4: The maximum displacemen alues and, ela i e o he e e ence, i s
pe cen ages o he la and cu ed geome ies. E (Mpa) and Thickness (mm)
pa ame e s ha e been conside o he analysis
Thickness
FLAT GEOMETRY 4 mm 5 mm
E
2890 MPa
Maximum displacemen :
9,54 mm
100% (Re e ence)
Maximum displacemen :
4,95 mm
-48%
8000 MPa
Maximum displacemen :
3,48 mm
-63%
Maximum displacemen :
1,78 mm
-81%
CURVED GEOMETRY 4 mm 5 mm
E
2890 MPa
Maximum displacemen :
8,38 mm
-12%
Maximum displacemen :
4,30 mm
-55%
8000 MPa
Maximum displacemen :
3,07 mm
-67%
Maximum displacemen :
1,57 mm
-83%
These esul s emphasize he impo ance o conside ing he pla o m
hickness, ma e ial s i ness, and pla o m geome y in he design o he
elec ic scoo e . The pa ame e s can ha e a signi ican impac on he
scoo e ’s s uc u al beha iou and, consequen ly, on i s sa e y and
pe o mance du ing use.
Once he p ope ies o he ma e ials de eloped in ESTELLA a e known,
calcula ions will be ca ied ou o de e mine which o he wo geome ies
will be manu ac u ed as a demons a o p o o ype.
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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3. Conclusions
In his deli e able, he p ocess o de ine he geome ies o he
demons a o s in oduced in deli e able 1.3 o he ESTELLA p ojec has
been desc ibed.
The i s demons a o , aimed a he cons uc ion sec o , is a window
p o ile designed o be manu ac u ed h ough esin cas ing loaded wi h
lignocellulose nano ib es on o a de achable ooling. This app oach
enables he p oduc ion o a p o ile wi hou using he mo e expensi e
pul usion p ocess, which is one o he con en ional manu ac u ing
me hods o cons an -sec ion p o iles in composi e ma e ial.
The second demons a o , a ge ing he leisu e/mobili y sec o , is an
elec ic scoo e pla o m designed o be manu ac u ed using a Resin
T ans e Molding (RTM) p ocess, employing a hemp ab ic imp egna ed
wi h high-pe o mance epoxy esin.
The designs ha e been made o u ilize he no el, na u al, and sus ainable
ma e ials de eloped in WP2, such as lignocellulose nano ib es and wo en
hemp ab ic, which ep esen a signi ican ad ancemen owa ds
sus ainabili y in he composi e ma e ials indus y. Once he inal ma e ials
ha e been selec ed and cha ac e ised, a de ini i e choice o
demons a o o each sec o will be made.
Fu he mo e, he selec ion o OOA manu ac u ing p ocesses no only
ensu es cos e iciency, bu also expands p oduc ion oppo uni ies o
companies lacking such acili ies, demons a ing he commi men o
inno a ion, sus ainabili y, and accessibili y o he ESTELLA p ojec .
G an Ag eemen 101058371 – P ojec ESTELLA
ESTELLA_D3.1_V04
©ESTELLA - This is he p ope y o ESTELLA Pa ies: shall no be dis ibu ed/ ep oduced wi hou o mal app o al o ESTELLA Gene al
Assembly.
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Bibliog aphy
[1] h ps://www.s ugal.com/si es/de aul / iles/ca alogo- en anas-
aluminio.pd
[2] h ps://www.en.une.o g/encuen a- u-no ma/busca- u-
no ma/no ma?c=N0057592
[3] h ps://www. oechling.com/indus ial/ echnology/pul usion
[4] Book: “Rheology and P ocessing o Polyme ic Ma e ials”. Volume 2
Polyme P ocessing. Chang Dae Han. ISBN: 9780195187830.
[5] Blog: E e y hing You Need o Know Abou Resin Cas ing
(h ps://www. ocheindus y.com/ esin-cas ing/)
[6] h ps://www.mi.com/es/p oduc /xiaomi-elec ic-scoo e -4-go/
[7] h ps://ceco ec.es/es/pa ine es-elec icos/bongo-d30-xl
[8]
h ps://www.hexcel.com/use _a ea/con en _media/ aw/RTM6_RTM62_H
exFlow_Da aShee .pd
