The EU-funded MORPHO project, which began in April 2021 and concludes this January, has delivered groundbreaking advancements in Structural Prognostics and Health Monitoring (SPHM), manufacturing optimization, and composite material recycling. By leveraging real-time monitoring, intelligent control systems, and innovative recycling techniques, MORPHO is redefining how industries approach structural integrity, production efficiency, and environmental responsibility.
At the heart of these achievements lies the development of smart aeronautical components with embedded life-cycle management systems. These innovations integrate advanced sensing technologies for real-time monitoring and address end-of-life sustainability challenges, supporting global efforts to improve resource efficiency and reduce environmental impacts.
“The integration of advanced Fiber Bragg Grating (FBG) sensors and printed piezoelectric transducers with innovative recycling techniques is a major step forward for aerospace manufacturing,” said Nazih Mechbal (Arts et Métiers Institute of Technology), project coordinator. “This work ensures not only improved performance and monitoring during operation but also a sustainable pathway for material recovery and reuse.”
Revolutionary SPHM Framework for Aerospace Components
The MORPHO project introduced a novel AI-based Structural Prognostics and Health Monitoring framework specifically targeting engine components such as fan blades. This innovative approach integrates low-frequency fatigue testing, advanced sensing techniques, and a deep learning architectures to predict stiffness degradation and Remaining Useful Life (RUL) base don strain and guided waves data.
A case study involving a Foreign Object Damage (FOD) panel subjected to cyclic loading demonstrated remarkable accuracy. For stiffness reduction, the average metrics across all folds included a Mean Squared Error (MSE) of 8.63, a Root Mean Squared Error (RMSE) of 2.58, and a Mean Absolute Percentage Error (MAPE) of 1.87%. Meanwhile, RUL estimation metrics achieved an MSE of 4192.3, an RMSE of 63.41, and a MAPE of 14.57% considering as End-of-Life a 1% global stiffness reduction of the FOD panels.
These advancements pave the way for a condition-based maintenance paradigm of aerospace components by enabling near real-time assessment of structural integrity.
Intelligent Resin Transfer Molding (RTM) Process Optimization
The MORPHO project has significantly advanced Resin Transfer Molding (RTM) for carbon fiber-reinforced polymers (CFRP). By utilizing advanced dielectric sensors and real-time data analytics, the team successfully achieved a 20% reduction in cure cycle times, equating to a 50-minute acceleration for standard cycles. This breakthrough was made possible through the development of robust, durable sensors capable of monitoring resin arrival, viscosity, and curing under industrial conditions. Complementing this, an online software system provided precise real-time monitoring of viscosity and glass transition temperature (Tg), enabling optimized cycle validation. These cycles integrated real-time data to enhance both efficiency and part quality. The streamlined RTM process represents a transformative leap forward, blending sustainability with cost-effectiveness to redefine manufacturing practices.
Breakthroughs in Sensor Technology and Real-Time Monitoring
Fiber Bragg Grating (FBG) sensors and printed piezoelectric transducers, embedded in engine components like FOD panels, demonstrated their ability to monitor strain, stress, and damage in real time during manufacturing and operation. These sensors enabled precise resin flow monitoring during RTM, facilitated Structural Health Monitoring (SHM) for long-term component integrity, and were integrated without compromising structural strength, underscoring their industrial viability. Printed piezoelectric and temperature sensors exhibited potential for broader applications, including the detection of impact damage and the monitoring of temperature changes in otherwise inaccessible areas.”
Sustainability Through Recycling and Laser-Shock Disassembly
MORPHO advanced sustainable manufacturing by developing laser-shock disassembly and pyrolysis techniques for recycling CFRP materials. These efforts resulted in the recovery of carbon fibers with less than 10% degradation in mechanical properties and the successful scaling of recovery processes to near-industrial levels, thereby supporting the circular economy. These achievements highlight the project’s commitment to environmental stewardship while addressing the challenges associated with composite material production.
The Hybrid Twin: Real-Time Simulation and Manufacturing Insights
One of the most advanced innovations of the MORPHO project is its hybrid twin of the Resin Transfer Molding (RTM) process, which seamlessly combines high-fidelity physics-based simulations with real-time data. This cutting-edge system has demonstrated exceptional capabilities, including achieving highly accurate predictions of resin flow and curing with a Mean Squared Error (MSE) of less than 1% in under 1 millisecond. Additionally, the hybrid twin technology enables real-time identification of local permeabilities in woven preforms, significantly enhancing quality control during production. By integrating this sophisticated approach, MORPHO allows for precise, data-driven adjustments throughout the manufacturing process, boosting productivity, improving component quality, and reducing waste.
About MORPHO
The MORPHO project is a HORIZON2020-funded initiative aimed at advancing manufacturing, repair, and recycling technologies for aerospace components. By integrating innovative sensor systems, disassembly methods, and recycling techniques, MORPHO seeks to enhance efficiency, performance, and sustainability in the aeronautical industry.
MORPHO, led by the Ecole Nationale Supérieure d’Arts et Métiers (ENSAM), is the joint effort of European experts in smart manufacturing, sensor integration, structural health monitoring, aerospace structural parts recycling, and SAFRAN (a major Original Equipment Manufacturer) in the area of aeronautics and air transport.
In total, MORPHO brings together 10 partners from six countries: Arts et Métiers (France); Technische Universiteit Delft (Netherlands); University of Patras (Greece); Safran Tech (France); Fraunhofer IFAM (Germany); Synthesites (Greece); Comet Group (Belgium); FiSens (Germany); ESI Spain (Spain); Fundación Empresa Universidad Gallega – FEUGA (Spain).