Surface functionalisation is present in a wide range of sectors, improving the performance of multiple components and systems in many applications. However, when considering the application of such functionalisation in complex industrial parts, several challenges must be faced. The difficulty of reaching all surfaces of complex 3D parts is significative, especially in those with considerable size and weight. At the same time, uncertainty about the regulatory compliance of functionalised parts in some sectors makes a straightforward integration of this process more difficult. As a result, this limits the potential of some companies in terms of opening up new markets or attaining a competitive edge. Additionally, the creation of functional surfaces has traditionally relied on processes such as chemical reactions and/or the complete coating of the native surfaces (e.g. aerofoils). Due to their very nature, these processes generate unwanted by-products thereby leaving a significant environmental footprint, which go against the “do no significant harm” principle of The European Green Deal. In order to avoid these setbacks, a new functionalising process for complex 3D shaped parts in which the environmental footprint is reduced and where new guidelines are generated to complement the manufacturing standards of target sectors, could be a game changer. BILASURF aims at developing and integrating a process for high-rate laser functionalization of complex 3D surfaces using tailored designed bio inspired riblets to reduce friction and improve the environmental footprint of industrial parts, assuring a high throughput with the help of inline monitoring capabilities. This solution can provide European industry with a key tool to use a more efficient and environmentally friendly manufacturing process.

SYNTECS brings together a consortium of industry leaders and academic and research organisations that are at the forefront of laser-based processing. SYNTECS is designed to tackle the multiple challenges experienced with current chemical and mechanical surface treatments. The overall aim of SYNTECS is to develop and demonstrate a digital and green laser texturing approach to generating complex multifunctional surfaces. A machine platform will be developed (TRL6), that enables interchangeable Direct Laser Writing (DLW), Direct Laser Interference Patterning (DLIP) and Laser Induced Periodic Surface Structuring (LIPSS), with a multi-axis motion stage for processing complex geometries and an inline monitoring and control system. The combined system will streamline the generation of hierarchical surface textures, i.e. textures which combine at least two significantly different sized features. The surface multi-functionality enabled by these hierarchical textures will be demonstrated in three industrial case studies: an injection moulding tool, a hip implant system and a complex shaped vapour chamber. Surface textures and texturing processes for these demonstrators will be designed using a Design for Surface Engineering software module, which will incorporate LCA guidance combined with predictive performance modelling to enable sustainable-by-design decision making. SYNTECS will demonstrate that hierarchical laser surface texturing provides a highly efficient and flexible route to replacing multiple (typically chemical and mechanical) energy and resources intensive surface treatments steps with a single, digitally controlled, chemical- and waste-free process.

Renewable energies provide clean, inexhaustible, and increasingly competitive energy source differing from fossil fuels in diversity, abundance, and potential for use. Solar energy capacity in European Union has been increasing in recent years with Germany, Spain and Poland leading the way in new installations. In 2022, the European Union added a record-breaking 41.4GW of solar power, increasing the total solar power capacity by 25%. Within the solar energy market, perovskite-based solar cells (PSCs) will contribute significantly towards the overall mix of solar energy due to PSCs differentiators compare to other solar Photovoltaic technologies of: (i) low-cost, (ii) excellent power-to-weight performance and (iii) high power conversion efficiency (PCE) of 25.7% at lab-scale in 2022, up from 3.8% in 2009. A key challenge of PSC technology is replication at large-scale as there is a substantial difference in performance from small-area cell (lab-scale) and large-area module performance. PERSEUS is designed to establish a foundation for PSC production and application development within Europe. The project will develop and demonstrate 3 different large area PSC architectures that offer broad adoption potential across multiple industries such as Floating Photovoltaics, Building Integrated and Applied Photovoltaics, Agri-Photovoltaics and Urban Photovoltaics. As each end-user requires different properties (e.g. performance, lifetime and cost targets), PERSEUS will develop parallel solutions to meet end-user needs covering: (1) single-junction opaque modules (2) semi-transparent modules and (3) 4T Perovskite + CIGS tandem module architectures. These will be translated into ‘blueprints’, of multi-stage manufacturing line(s) which have validated, matched outputs and allow immediate post-project progress to the commercialization phase.