The INLINE project aims at the solution of key challenges to enable the implementation of a scalable manufacturing process for fuel cell systems. Current manufacturing processes rely on manual work that has substantial limits in terms of cycle times, costs and scalability. Developments will start with the re-design and optimization of two key components: the media supply unit and the tank valve regulator. Both are components that are currently difficult to manufacture and are perceived as bottlenecks in the production process. Based on these new designs, an integrated production line will be planned using simulation tools. These tools will enable the evaluation of different layouts, part flow strategies and for different production scenarios. In terms of manufacturing tools, the end of line test will be improved to reduce cycle times by a factor of 3 and assistance systems for assembly stations will be developed that will enable scalability by reducing the need for training of workers. The overall target is to reduce the cycle time for production of a whole fuel cell system from 15 hours to less than 2.5 hours. Data gathering and analysis methods will be developed to enable the tracking of parts through the production line and - through a correlation of process and quality data - the continuous improvement of the production process. Demonstration of the end of line test and the assistance system will be done in hardware. The whole production line will be evaluated using a simulation tool that has been verified on the current production process. A set of engineering samples of the re-designed tank valve regulator and the media supply unit will be produced and used for tests of the integrated fuel cells and for assessment of the whole production process.A potential of 250 new jobs in manufacturing of fuel cells and for production of the key components will be generated by the project.

The main goal of HEAVEN project is to design, develop and integrate a powertrain based on high power fuel cell and cryogenic technology into an existing 2-4 seats aircraft for testing in flight operation. Specifically, the project proposes to design a modular architecture with modular systems that can be scale-up to other sizes of aircrafts and UAV applications. The design methodology is complemented with safety and regulation analysis. Regarding the fuel cell technology, two high power PEM fuel cell systems of 45 kW based on metallic bipolar plates will be adapted for aircraft applications and integrated with optimized balance of plant components to obtain an enhanced 90kW fuel cell system able to propel without support of a battery the aircraft operating modes. The hydrogen storage will be based on cryogenic technology successfully applied in previous space applications in order to achieve a gravimetric index of about 15% for a hydrogen payload between 10 and 25 kg that provides an autonomy range to the demonstrator of 5-8 hours. Moreover, HEAVEN project will leverage existing drivetrain components and an aircraft demonstrator in order to achieve an overall and successful TRL6 at the end of the project. The technology developments will be enriched with economic and business assessments during the execution of the project. Thus, HEAVEN will produce estimations of a total cost of ownership for the entire life cycle of the technology and business plan for the deployment of the technology in different aeronautics applications. Finally, HEAVEN consortium comprises large companies, SMEs and well-known research center with a strong experience and knowledge in fuel cell technology development for aeronautic applications that is supported with the participation in previous relevant H2020 projects and national projects.

The global objective of the Spartacus project is to develop an affordable sensor solution to detect degradation and failure mechanisms, intentionally before a loss of performance. The project will focus on mechanical and acoustic sensors completed by electrochemical impedance measurement and temperature sensors. The sensoric data will be correlated to battery performance and to corresponding models. The state of different parameters (SoX) will be monitored continuously which enables the management system to cycle the battery on an age-dependent optimum level. An advanced Battery Management System (BMS) will be developed. BMS will work in proximity to the cells terminals (i.e. a cell management system, CMS) to efficiently exploit all the sensoric data without extra-wiring harness. At the end of the project, an 24V smart battery module will be assembled and the CMS enhanced by the senoric data will be validated in different ageing conditions or for misused or abused batteries at lab-scale (TRL4). Quantitatively, a reduction of 20% charging time without any negative effect on life time by exploitation of sensoric data is targeted. By usage of sensoric data, cell monitoring will be also improved and will increase the safety of batteries and avoid overheating (thermal runaway), fire or explosion. Spartacus project is based on 6 specific objectives: - OBJ1: Development of new sensors design for smart batteries - OBJ2: Integration of the sensors according to industrial constraints incl. Packaging / Assembly technology - OBJ3: Data acquisition and data pre-processing for BMS integration - OBJ4: Modelling of failure mechanisms and correlation with SoX - OBJ5: Development of an advanced BMS and standardization procedures - OBJ6: Economic and environmental assessment Spartacus consortium is a strong partnership of 5 European research centres and 1 leading industrial having extensive track-records in materials, battery, sensors, modelling, BMS and associated domains.

The principal aim of the project is to develop an EU-centric supply base for key automotive PEM fuel cell components that achieve high power density and with volume production capability along with embedded quality control as a key focus - to enable the establishment of a mature Automotive PEM fuel cell manufacturing capability in Europe. It will exploit existing EU value adding competencies and skill sets to enhance EU employment opportunities and competitiveness while supporting CO2 reduction and emissions reduction targets across the Transport sector with increased security of fuel supply (by utilising locally produced Hydrogen).

qSOFC project combines leading European companies and research centres in stack manufacturing value-chain with two companies specialized in production automation and quality assurance to optimize the current stack manufacturing processes for mass production. Currently the state-of-the-art SOFC system capital expenditure (capex) is 7000…8000 €/kW of which stack is the single most expensive component. This proposal focuses on SOFC stack cost reduction and quality improvement by replacing manual labour in all key parts of the stack manufacturing process with automated manufacturing and quality control. This will lead to stack cost of 1000 €/kW and create a further cost reduction potential down to 500 €/kW at mass production (2000 MW/year). During the qSOFC project, key steps in cell and interconnect manufacturing and quality assurance will be optimized to enable mass-manufacturing. This will include development and validation of high-speed cell-manufacturing process, automated 3D machine vision inspection method to detect defects in cell manufacturing and automated leak-tightness detection of laser-welded/brazed interconnect-assemblies. The project is based on the products of its' industrial partners in stack-manufacturing value-chain (ElringKlinger, Elcogen AS, Elcogen Oy, Sandvik) and motivated by their interest to further ready their products into mass-manufacturing market. Two companies specialized in production automation and quality control (Müko, HaikuTech) provide their expertise to the project. The two research centres (VTT, ENEA) support these companies with their scientific background and validate the produced cells, interconnects and stacks. Effective exploitation and dissemination of resulting improved products, services, and know-how is a natural purpose of each partner and these actions are boosted by this project. This makes project results available also for other parties and increases competitiveness of the European fuel cell industry.