KAIROS

intelligent and automated 4.0 manufacturing of large composite naval parts

The aim of the KAIROS project is to research cutting-edge composite manufacturing technologies, Industry 4.0, and Digital Twin solutions, in order to develop an efficient manufacturing process for large composite components for the naval sector. The solution will offer a high degree of automation, superior quality, and cost optimisation.

Challenges

Develop a composite material with properties comparable to steel, using raw materials that are affordable and meet the required physical and mechanical performance standards (mechanical strength, fire behaviour, corrosion resistance, etc.)—preferably of sustainable origin.

Select digital and physical tools and technologies that provide participating companies with a valuable pre-selection of options to advance their industrial processes towards Industry 4.0, including innovations such as digital twin technologies.

Achieve high-quality preforms and stiffeners without compromising resin permeability during the subsequent infusion process, ensuring the final performance of the part.

Ensure that the final composite components include all necessary metal inserts for integration into the structures they will form part of, alongside other components.

Guarantee zero defects in composite parts produced for the nautical sector through infusion processes, achieving 100% automation and digitalisation by applying computer vision to ensure manufacturing reliability.

Reduce the development time for comparable products by at least 33% compared to current general composite development methodologies.

Solution

The project’s objectives will be achieved through research into technologies such as new lightweight composite materials, automated manufacturing processes, computer vision, sensorisation, artificial intelligence (AI), and digital twin systems.