The main objective is to boost the company’s innovation capacity by conducting research on new optical fibre distributed sensors. This requires development of the specialised skillset within the company on optical fibre phenomena such as Rayleigh, Raman, Brillouin, and Coherent Rayleigh scattering. Hence the main goal is to overcome barriers of recruitment of highly specialised researcher and to recruit the specialist, who will be an initiator of the innovation potential growth in InPhoTech The idea of the optical fibre distributed sensors follows a global trend in the global market for sensors and is a direct answer to the number of inquiries addressed to InPhoTech. The optical fibre distributed sensors allow to monitor critical infrastructure and manufacturing processes. Within the project we answer the European and global demand for reliable optical fibre sensing system, driven by need of connecting more and more sensors into IoT (Internet of Things), integration and miniaturisation of sensors, as well as the demand for accurate and early diagnosis devices in an effort to increase safety in industry.

We are on the verge of 5G arrival, the new standard bringing much higher speeds and more reliable connections to millions of end users and possibly billions of connected IoT devices. 5G networks require many more small sites than other cellular systems, and the industry agrees that their demand for bandwidth can only be met with fixed optical fibre connections. These are not available in many locations, and space in existing cable ducts is limited while accessing them is costly. At the same time, even at the speed of light, current Single-Mode Fibres have reached their theoretical capacity limit. Global IP traffic demand for urban fibre networks is forecast to grow at a blistering CAGR of 45% in the coming years. The problem is that current fibre infrastructure cannot continue to support the foreseen demand without an upgrade to carry the increased traffic beyond its theoretical capacity. However, deploying a completely new infrastructure is costly and therefore, not an option. It is a challenge to meet the growing demand using the existing infrastructure – this requires a new approach. At InPhoTech, we see this “Capacity Crunch” as an opportunity. Our patented IPT-CORE telecommunication technology uses seven cores in every single microstructured fibre as separate spatial channels, allowing the most effective use of our well-developed multiplexing methods to increase optical throughput seven times in the same physical space. By being fully compatible with existing infrastructure, IPT-CORE provides a cost-effective replacement for target customers such as 5G operators, providers of FTTx services, Long Distance Connections and Data Centres. Our ultimate goal is to become the world’s first mass-scale multicore optical fibre supplier, putting the EU at the same level as the US and Asia as global fibre providers. The technology will be held by InPhoTech and will generate a growth impact for the company of €23 million in profit 5 years after deployment.

The DISCO2030 project aims to develop two innovative hybrid manufacturing methods for joining dissimilar metal-metal and metal-polymer materials. Both proposed methods are underpinned by additive manufacturing (AM) technologies from the emerging technology families of Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). DISCO2030 combines the advantages of PBF and DED to enable the manufacturing of multi-material lightweight, complex geometry components/structures that are able to operate in harsh environments. The process is expected to achieve a ≥20% lead time reduction compared to state-of-the-art manufacturing processes (such as die casting and brazing) and manufacture multi-material parts that have a 50% lower weight compared to reference products and a 30% higher performance (achieved among others by graded materials). The three use-cases to be demonstrated in the project are of high relevance to the EU economy and include a rocket engine, a marine engine and a cryogenic hydrogen tank for primary applications in the automotive sector. All components manufactured using the novel DISCO hybrid manufacturing methods will be subjected to rigid testing according to the respective industry standards. DISCO2030 is expected to generate significant impact by paving the way for the creation of new dissimilar material joining and testing standards, strengthening the EU’s leadership in AM technologies and increasing the EU’s resilience against global supply chain disruptions. Finally, DISCO2030 will contribute to the reinvention of the European aerospace, marine and automotive sectors, ultimately providing EU citizens with better, more sustainable and cost-effective transportation.

Additive manufacturing (AM) technologies offer unique advantages over conventional production processes, such as an efficient material usage through near net shape manufacturing and the high degree of freedom of design. Moreover, dissimilar materials can be joined into single components, which is the focus of the Horizon Europe project DISCO2030. By building components layer by layer, another ground-breaking potential of AM comes into play: the integration of sensor systems, e.g. optical fibre sensors, at virtually any location within a part, thereby allowing for structural health monitoring and continuous data acquisition within critical components, such as the DISCO2030 use-cases. However, there are still technological barriers towards the integration of optical fibre sensors into AM parts, especially in metals featuring a high-melting point as the high temperatures during AM can damage the sensors. Therefore, this hop-on project follows a holistic path towards a successful integration of optical fibre sensors in a wide range of materials. First, the hop-on partner InPhoTech, specialized in optical fibre technology, will develop coatings that protect the sensors from damage due to the AM processes. Second, adaptations for different AM processes are developed in order to ensure a seamless integration of the sensors into the parts. Third, the sensing capabilities and the impact of the sensors on component performance are evaluated. Through the incorporation of optical fibre sensors, the high functionality of AM parts is even more increased, opening up new opportunities. For instance, the increased information depth collected from critical parts during testing or operation allows for improved designs. By showcasing the potential of optical fibre sensor integration, this project paves the way to a more widespread use of this technology, thereby leading to technological and economic advantages for European companies.