The MORPHO project redefined the future of Resin Transfer Molding (RTM) by integrating cutting-edge technologies to create an intelligent, adaptive manufacturing framework for high-performance composite parts. Through the seamless combination of robust dielectric sensors, fiber Bragg grating (FBG) sensors, real-time physics-based simulations, and hybrid AI models, MORPHO set new benchmarks in precision, efficiency, and scalability for advanced composite production.
Transformative Achievements in RTM Technology
The MORPHO hybrid twin combined a reduced physics-based model with an “ignorance model” correction to bridge the gap between simulation and real-world data. By using sparse proper generalized decomposition (s-PGD), the team reduced high-fidelity simulations, which traditionally took five hours to compute, to real-time predictions completed in under 1 millisecond, with mean squared errors below 1%. This allowed unprecedented responsiveness and control during manufacturing processes.
Dielectric cure sensors, seamlessly integrated into the mold, and FBG sensors, integrated into carbon fiber composites, monitored critical parameters such as resin flow, arrival time, viscosity, and curing progression. The sensors’ placement and real-time feedback enabled precise identification of local permeabilities within woven preforms, drastically improving mold-filling accuracy.
“Through the MORPHO project, we’ve demonstrated that real-time monitoring and hybrid AI can reshape the future of composite manufacturing,” said Eric Monteiro, researcher at Arts et Métiers Institute of Technology. “This achievement bridges the gap between high-performance demands and cost-efficiency, offering an innovative path forward for lightweight and sustainable composite structures.”
Applications and Results
The MORPHO framework excelled in addressing the challenges of producing aerospace-grade composites with superior quality and efficiency. In testing, the hybrid twin achieved a 98% success rate in manufacturing aerospace components, significantly reducing cycle times by up to 50 minutes per part. These advancements not only optimized productivity but also contributed to reduced waste and enhanced thermal management.
The system’s ability to predict flow front positions and filling times with sub-5% error rates has redefined precision in mold filling, making MORPHO’s RTM framework a potential industry standard for composite manufacturing in aerospace, automotive, and beyond.
A Collaborative Triumph
The project was driven by an ambitious vision: enabling real-time dialogue between simulations and experimental setups for embedded life-cycle management of smart multimaterial structures. The hybrid twin’s applications extend beyond aerospace, paving the way for intelligent, sensor-driven manufacturing systems that meet the growing demand for lightweight, durable, and cost-effective components.
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).