GEARUP

Green Engineering, Analysis, &

Reskilling for Unbounded Production

What is GEAR-UP?

How do we improve the use of secondary materials in additive manufacturing? That is one of the main driving forces behind the GEAR-UP project. By developing digital tools and methodologies we can adress the variability of recycled materials.

The project aims to promote resilient design and life-cycle environmental impact assessment to tackle challenges related to the perfomance and conistency of secondary materials. The project centers on materials like stainless steel, aluminum alloys, and fiber-reinforced plastics for additive manufacturing.

With a strong emphasis on environmental sustainability and conservation, GEAR-UP integrates recycled materials in engineering design, significantly reducing virgin resources, energy consumption, and greenhouse gas emission.

GEAR-UP’s approach represents a paradigm shift in engineering design, focusing on the circular values chain and developing universally adaptable additive manufacturing technologies resilient to material variability.

Materials

The GEAR-UP initiative aims to revolutionize manufacturing by developing digital tools to optimize additive manufacturing processes using recycled materials.

Conservation

It focuses on environmental conservation by reducing reliance on virgin resources, minimizing emissions, and addressing performance variability in secondary materials.

Sustainable design

The project advances sustainable product design through digital modeling, circularity initiatives, and global collaboration, impacting industries like green energy and high-tech robotics.

key outcomes

The integration of simulation tools into the GEAR-UP platform.

Create a methodology for single-objective topology design optimisation.

Developing a semi-automated Digital Product Passport (DPP) framework.

Developing and optimising three types of recycled textile-based masterbatches with enhanced properties.

Process optimisation using simulations takes into account the chemical differences in recycled materials to determine the best build parameters.

Creating a method for predicting material behaviour variability and predicting specific products’ environmental impact.

Partners

GEAR-UP thrives on strong collaboration with our partners to drive circularity and sustainable technology adoption. Through global networks and specialized training programs, we ensure knowledge sharing and innovation across industries. By working together, we develop resilient solutions that push the boundaries of sustainable manufacturing.