The main objective of Project POLISURF is the design and development of new polymeric products with surface properties similar to metals through the use of industrializable, sustainable, and environmentally friendly materials and technologies.

To achieve the main objective, Project POLISURF must also reach a series of specific objectives, as detailed below:

• Application of sustainability and eco-design criteria: To minimize the environmental impact of new developments, the application of sustainability criteria from product conception to the end of its life cycle will be necessary. Starting from these concepts, Project POLISURF will apply this eco-design and sustainable design systematic to all newly designed products.
• Development of sustainable polymeric formulations: The development of custom sustainable polymeric formulations for each application will allow obtaining suitable substrates on which to apply different surface treatment technologies to obtain new products with a high innovation component.
• Development and application of surface treatment techniques: The contribution of specific surface properties (aesthetic, functional, and haptic) will be made through the development of environmentally friendly metallic technologies that are competitive for future industrialization processes and, moreover, allow the recovery of plastic and metal for reuse
• Study of manufacturing technologies for new materials: These technologies will allow new design possibilities, recycling, and material hybridization. The use of conventional technologies such as the injection molding process will be combined with the exploration of more advanced techniques such as Additive Manufacturing. It will be necessary to adapt surface technologies for their application to parts obtained by Additive Manufacturing, a sector that is continuously growing and requires competitive and innovative solutions to develop new surfaces with high aesthetic, functional, and haptic properties.
• Life cycle analysis, environmental assessment, and cost analysis: The evaluation of the environmental impacts of new polymeric products will establish the degree of improvement compared to previous products and materials, ensuring that new solutions have a lower environmental impact throughout their life cycle. The development of new solutions whose environmental efficiency is demonstrated simultaneously with their development will allow effective environmental communication. Also, the evaluation of the economic aspects of the materials and processes developed will be a key factor both in the industrial viability of the project and to demonstrate that there will be no cost transfer to the later stages of the life cycle (use, maintenance, and end of life).

To successfully achieve the proposed objectives in Project POLISURF, a Consortium of leading companies in their respective business areas has been formed to address the development with sufficient guarantees of success. It is worth noting that the participating companies in the project have the necessary means and technology to address its development with the support of the Basque network of Technological Centers.

The Consortium that will carry out the activities encompassed within the task packages of Project POLISURF is composed of the following companies: INDAUX as the project leader, DHEMEN, IK-INGENIERÍA, IRURENA GROUP, MAIER, ONDARRETA, DAISALUX, ABB NIESSEN, and HABIC as participants.

The purpose of the INTELCOM project is to develop intelligent composite streetlights for 5G telecommunications infrastructure.

Communication needs are increasing in various areas such as mobility (autonomous driving), smart cities (avenues), sports venues (football stadiums, basketball arenas…), university campuses, technology parks, industrial parks, conference centers, trade fairs, airports, etc. In all these infrastructures, tubular structures with mechanical requirements (streetlights, bus shelters, spatial structures of domes and roofs, etc.) can be found, where telecommunications antennas are installed.

However, since they are mostly metallic components, antennas are placed outside the structure, resulting in visual impact and vulnerability to vandalism or adverse weather conditions. Fiberglass-reinforced composites are partially transparent dielectric materials to electromagnetic waves, so the manufacturing of tubular structures would allow the safe integration of 5G antennas inside without exposing them.

The differentiating value of the INTELCOM project lies in the possibility of manufacturing curved tubes through the pultrusion process with UV curing outside the mold and pulled by a robot, allowing a high level of flexibility in production (easy, fast, and reliable machine reconfiguration). Additionally, the new pultrusion machines will be portable, so profiles can be manufactured on-site, avoiding logistical problems inherent in large structures. IRURENA, in collaboration with MONDRAGON UNIBERTSITATEA, has developed this unique technology in the world and has demonstrated its validity for manufacturing components for the automotive industry.

This project aims to demonstrate the validity of the technology in a strategic sector, such as telecommunications infrastructure, so that the new manufacturing process can be consolidated and contribute to strengthening the Basque Country in the field of Advanced Manufacturing.

We are part of the ECOBIOFOR Project, a project funded by the European Commission under the 7th Framework Programme (FP7, SME-2013, GA: 605215). It started on September 1, 2014, and is expected to conclude at the end of November 2016.

The main objective of the ECOBIOFOR project is the development of new bio-solvents using renewable resources via innovative biotechnological and chemical processes based on the principles of green chemistry. These bio-solvents aim to replace those of petrochemical origin commonly used in the paint, varnish, and coating industries, promoting more sustainable production and consumption.

The coatings industry requires more environmentally friendly components for the formulation of coatings, inks, adhesives, paints, and varnishes, as solvents are one of the main and basic components in their formulations. The R&D project responds to the sector’s need to introduce more environmentally friendly products into the market.

The development of these “bio-solvents” is a clear example of the potential that biotechnology application offers at an industrial level, providing patentable technical results and economically viable outcomes in the form of new products and technologies. This approach enhances the transition of the European paint, coatings, and solvent industry from a petroleum-based chemistry to a biotechnologically based and more sustainable one.

In this way, ECOBIOFOR boosts the coatings sector and biotechnological companies, facilitating the manufacturing of “bio” products with higher added value. This is achieved through the development of a new generation of paints with a reduced carbon footprint while maintaining their performance and properties.

The consortium includes the following organizations:

• 5 associations of SME companies, comprising three biotechnology associations and two paint associations, with a total of 1349 members (1009 SMEs).
• 3 companies, one chemical product manufacturer (Industry), and two paint manufacturers (SMEs).
• 3 Research and Development centers with previous experience in Green Chemistry, organic and biotechnological synthesis, and paint formulation.

Additionally, as members of an external committee of experts, the consortium collaborates with experts from ABENGOA BIOENERGIA NUEVAS TECNOLOGIAS and IHOBE to provide green raw materials and support and provide recommendations on green policy strategies.

The overall objective of the CONFORT Project is the conceptualization and development of new customized features for comfort in the interiors of PREMIUM-LUXURY vehicle platforms with VISION 2021, using advanced materials and surfaces.

From this general objective, a series of specific objectives are derived, broken down into technological, strategic, economic, and environmental aspects:

Technological objectives:

• Manufacture components for car interiors using different plastic and metal materials with innovative comfort features, using design and virtual reality tools, digitalization, connectivity, and surface treatments.
• Integrate the products into a car demonstration platform (SCP 4.0), combining the comfort requirements of the PREMIUM-LUXURY car interior demanded by the market with advanced manufacturing technologies, ICT, and adaptable, versatile, non-toxic component-free surfaces that are easy to industrialize.
• Develop procedures for capturing user perceptions, desires, and needs, and consumer-oriented product development, for application to the definition of the SCP 4.0 platform prototype and its manufacturing.
• Develop design and virtual reality tools, CAD modeling, and PLM/PDM applied to the development and industrialization of vehicle interiors.
• Develop modeling and simulation tools for the mechanical, acoustic, and thermal properties of the new car interior components.
• Incorporate multipanel technology into the SCP 4.0 platform’s interior that allows content sharing, interaction, and personalized experiences.
• Incorporate intelligent methodology that allows controlled, reproducible processes adapted to the continuous changes in requirements from automotive manufacturers and vehicle users.
• Develop new formulations for highly mechanically resistant omniphobic coatings and ensure the durability of their finish and resistance.
• Improve the adhesion of coatings to polymeric substrates through the development of surface pretreatments.
• Develop surface modification processes on plastic and metal components that are robust, repetitive, and industrializable, offering new aesthetic comfort features.
• Establish a characterization method for evaluating modified surfaces that allows control of the process and the final product.

The Consortium that will develop the project is composed of the following companies: ALEGRIA ACTIVITY as the project leader and SEGULA, MAIER, IRURENA GROUP, HETTICH, ROTOBASQUE, OPTIMUS 3D, and EKIDE as participants.

The goal of the AMWOOD project is to revolutionize the distribution chain of transparent wood dyes by providing the market – globally – with a system capable of allowing the distributor to formulate ready-to-use transparent dyes at their own location.

Like opaque paint, we aim for the customer to leave with their dye prepared and ready for use on the chosen substrate and for the intended type of application. A compact solution is being developed that makes use of low-cost hardware that can be easily installed by the customer.

The system will calculate which concentrated dyes and in what quantity they should be mixed, and if necessary, it will manage communication with the manufacturer.

Currently, there is no method for the automatic formulation of transparent wood dyes. Developing this method is the greatest scientific-technological challenge of the AMWOOD project. With this new method, the entire process of color capture, formulation of the new dye, and stockpiling of materials needed by a dye distributor is proposed to be improved.

How does Amwood work?

The dye distributor receives an order from a customer who sends in a veneered wood or with a specific color tone and demands a dye that will produce the same result on a veneer or solid wood that may be similar or different from the sent sample. As there is no automatic method for dye formulation, and due to the complexity of the task, the distributor often must refer the problem to the manufacturer of the pigments and solvents that make up the dye. The manufacturer is also informed of the application method, according to which the dye must be deposited once formulated.

The manufacturer, knowledgeable about the properties of each pigment and solvent, estimates a mixture of materials to achieve the desired dye. They must select from their catalog not only the types of pigments and the solvent to be mixed but also the proportion in which each of these substances will go into the mixture. In other words, they must estimate the formula of the dye. The manufacturer sends the mixture to the distributor, and the distributor tests it in their facilities. If not satisfied with the result, the above process is repeated until the manufacturer achieves a satisfactory mixture for the customer. Once the mixture is achieved, the manufacturer produces it in the volume required by the distributor. This iterative process is inefficient, slow, and incurs additional costs for both the manufacturer and the dye distributor.

With AMWOOD, we aim for the dye distributor to have greater autonomy and be able to design the dye mixture themselves or estimate what materials and in what quantity they need to supply. For this, we need a compact and low-cost system, thus discarding expensive and inefficient spectrophotometers for this task. The use of a photo scanner will be studied to digitize wood samples for subsequent processing, and the mixture estimation module will be based on Artificial Intelligence techniques to formulate the optimal mixture. These steps will be included in a computer application that will also calculate the quantity of materials needed for a specific job and manage communication with the manufacturer.

The AVACO project aims at the automation of the manufacturing of composite frames for small and medium-sized boats (up to 50 m). To achieve this goal, it is essential to provide the shipbuilding industry with new advanced manufacturing processes capable of meeting not only the technical requirements of the components but also the needs of the transportation industry.

In this regard, AVACO is focused on optimizing the pultrusion process with ultraviolet (UV) curing outside the mold, which allows the manufacturing of curved composite profiles with high flexibility and a high degree of automation, addressing two of the most critical issues in the sector:

• Lightening structures through advanced materials, such as composites.

• Automating manufacturing processes through robotics and the use of alternative curing techniques (UV curing).

Regarding the first point, composites remain and will continue to be present on the strategic agendas of industries associated with the transportation sector, such as the naval industry. This is because composites are a key element in reducing environmental impact through structural lightening. In fact, the adoption of composites by the naval industry began in the 1950s and has been increasing ever since. An example of this is that most recreational boats, sailboats, patrol boats, or rescue vessels are manufactured with these materials (lengths of less than 50 meters).

Due to the high number of such vessels in European maritime transport, their environmental impact cannot be underestimated. It is essential to continue adopting solutions that encourage the sector to increase the use of composites in these vessels and even in larger vessels, leading directly to the second point.

Currently, the manufacturing of composite vessels is done in an extremely manual, almost artisanal manner. This involves high production costs due to the requirements of highly skilled labor, low production rates, or low-quality control, among others.

In this regard, if we examine the specific case of manufacturing the frames of a boat’s hull, the latter point becomes even more important, as each of the frames must have a different geometry to adapt to the shape of the hull. This requires the manufacturing of expanded polyurethane preforms, which are machined to the specified size, adhered to the boat’s hull, and then manually laminated.

 

This technique results in the over-sizing of the frames due to the low quality control during lamination, as well as the use of materials like expanded polyurethane that does not provide any benefit during the vessel’s lifespan. In fact, it can rot in service due to water infiltration.

 

Therefore, the introduction of manufacturing processes in the naval industry that allow the economically viable use of composites is crucial for the modernization of Basque and European shipyards. As mentioned at the beginning of this section, the UV pultrusion process allows the production of curved structural profiles with a high level of automation and production rate.

Achieving the goals of the AVACO project constitutes a notable technological challenge but also involves research and the generation of new knowledge in fields as important as advanced manufacturing, materials engineering, or robotics. Additionally, the implementation of UV pultrusion technology in the naval industry will signify a paradigm shift in the sector.

The reduction in manufacturing costs will lower the final cost for the customer, thus leading shipyards to increase their annual production of composite vessels. Consequently, this provides the Basque industrial sector with a differentiating technology that will be unique in the world.

 

“Action co-financed by the Basque Government and the EU through the European Regional Development Fund 2014-2020 (ERDF).”

We had the opportunity to participate as guest speakers by Ihobe, the Public Society of Environmental Management of the Basque Government, in collaboration with Aclima, the Basque Cluster of Environment, in the free online event of Thursday of Ecoefficiency – Ekosteguna: European Ecolabel. A key instrument in the European Green Deal market, to showcase our experience in the use of the Ecolabel.

But first of all, in case you’re not familiar with it, what is the EU Ecolabel?

What does EU Ecolabel mean?

The EU Ecolabel, or European Ecolabel, is the official European system for recognizing and identifying environmentally friendly products and services. It is a truthful, rigorous, and voluntary system that aims to promote products and services characterized by a lower environmental impact, thus contributing to an efficient use of resources and a high level of environmental protection.

Its goal is to provide an easy and direct way to identify a product and/or service that is environmentally responsible, backed by accurate, non-misleading, and scientifically based information. Created in 1992 (and therefore with almost 30 years of history), it is still not well-known or recognized by consumers.

After learning what the Ecolabel is, we can summarize it in a quote:

“Ecolabel is a seal that identifies products that exceed the quality standards of their category, respecting the environment and guaranteeing their behavior and durability.”

Together with Astigarraga Kit Line and A&B Innovative Solutions, Basque companies, along with Irurena Group, pioneers in the use of the Ecolabel, we had the opportunity to present its characteristics, show its benefits, and share our experience since we decided to opt for environmentally friendly products.

With events like these, the intention is, on the one hand, to encourage manufacturers to produce products with a lower environmental impact and inform companies and distributors about the benefits of selling products with the Ecolabel. And, on the other hand, to promote knowledge of the label among the public so that they are aware of and purchase products with the label that certifies the ecological management of the products.

What are the advantages of the Ecolabel?

There are many advantages of the Ecolabel; to name a few, we can say that:

• It leads us to use fewer resources (energy, raw materials…).
• Development of Premium products.
• Better position against future challenges (regulations, contracts…)
• Favors the defense and protection of nature thanks to the reduction of the environmental impact of products.
• Marks a clear differentiation from products that cannot obtain the label.
• Is valid throughout Europe.

In short, the use of the Ecolabel motivates us to constantly innovate in the development of healthier varnishes and paints. Achieving a wide range of ecological coatings for all types of surfaces outdoors and indoors that differentiate us in the market.”

Transparent 100% solid wood varnishes (solvent-free) for curing with ultraviolet LED lamps.

The Final Degree Project carried out by Iker Hidalgo Gallardo, a graduate from the Faculty of Chemistry at the University of the Basque Country, is a significant step in the world of wood varnishes.

During his collaboration with Irurena Group, he has developed transparent 100% solid wood varnishes, without solvents, which cure through ultraviolet LED lamps.

These varnishes represent a significant innovation as they aim to replace the mercury and gallium lamps used in the wood industry, not only reducing toxicity but also opening the door to greater efficiency in the curing process.

UV LED lamp technology offers significant advantages, such as lower heat emission, portability, and lower energy consumption.

Through thorough research, supervised by Aitziber Muguerza, an R&D specialist in UV curing at the company, Iker has succeeded in formulating a product that meets the necessary requirements for a high-quality wood coating.

His work is an example of how science and chemistry can revolutionize the wood industry and anticipate future constraints.

This achievement is a testament to the potential of research and innovation in improving products and processes in the industry.

Discover Iker’s work by clicking here.

The HARITZA project (Oak, Quercus robur in Latin, sturdy, with strength and perseverance) aims to persist in the research for the recovery of complex waste in the metallurgical sector.

Given their properties, metals can be recycled almost infinitely. Therefore, the metal recycling value chain in the EU and particularly in the Basque Country contributes to reducing dependence on imported materials and ensures the supply for the manufacturing and maintenance of basic infrastructures (construction, communication, transportation, etc.).

In this scenario, the foundry industry plays a crucial role in the recycling of metallic materials. Scrap from the end of the life cycle of steel, iron, aluminum, or copper components can be melted down and transformed into new products through foundry processes.

But this industry is not without a significant environmental impact, as, to recycle metal, companies in this sector generate waste and emissions that need to be captured, recycled, and valorized. Millions of tons of waste are discussed every year that must be disposed of with the use of means and high costs.

According to the data collected by the Basque Statistical Yearbook 2020 prepared by EUSTAT, 27% (929,434 tons) of non-hazardous waste generated in the Basque Country in 2017 came from the Thermal Processing Industry. Of these, 48% are recycled or reused, and 52% (482,909 tons) are disposed of in landfills.

The metallurgical industry faces three challenges to achieve the goals outlined in the 2030 agenda. Circular economy is a vital part of a smart industry. Therefore, the recovery of various types of complex waste from the metallurgical industry that allows inertization and reuse in the plant itself or in other industrial solutions is sought, aiming for economic viability with a reuse rate exceeding 90%.

Considering both solid, liquid, and gaseous waste, all are considered for recovery. Some of these solids are recovered or treated for use, but many are dumped, such as foundry sands, slag, chips, and scale with many oils. The CHALLENGE is to economically recover, with zero-carbon emission technologies related to the complex residual materials of the metallurgical industry, allowing them to be reused in the plant itself or inertized for use in other industries. An example is inertizing scale and slag for use as raw materials in foundries and steelworks or for new refractory products in low-temperature furnaces.

IRURENA aims to reuse these wastes as raw materials in its formulations for additive manufacturing for subsequent use in foundries.

“Action co-financed by the Basque Government and the EU through the European Regional Development Fund 2014-2020 (ERDF).”

In the 32nd edition of the Toribio Echevarria Awards 2022, Robtrusion has been honoured with the award for the best new company.

These awards recognise and promote innovative entrepreneurship and the creation of new business projects within the industrial framework of the Basque Country.

Ideas that have the potential to become a business reality become nominees for the award.

A significant innovative project, which, with the effort and enthusiasm of a great team, is succeeding in offering something new to enhance industrial processes. This activity has been acknowledged by the jury of the Toribio Echevarria Awards.

Thank you for granting us the award, and congratulations to all the individuals who are part of the Robtrusion team.

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