Elias P. Koumoulos’s research while affiliated with CMC Solutions Belgium and other places

The European Union’s commitment to significantly reducing greenhouse gas emissions by promoting renewable energy necessitates a comprehensive understanding of the societal impacts of these initiatives to achieve sustainable development. A significant challenge lies in effectively assessing the social impacts of the wind and tidal energy sector. This paper addresses this issue by presenting an expanded methodology derived from the Sustainable Development Goals (SDG) Impact Assessment, specifically tailored to assess social impacts. The methodology focuses on social SDGs, particularly Good Health and Well-being (SDG 3), Gender Equality (SDG 5), Affordable and Clean Energy (SDG 7), Sustainable Cities and Communities (SDG 11), and Partnerships for the Goals (SDG 17). Irrelevant targets are excluded based on defined criteria, while the remaining targets are characterized according to their impact pathways, validated through peer review, and prioritized by experts. The results underscore the importance of strategic partnerships, innovative material development, and gender equality in achieving global sustainability objectives. This research offers valuable insights into integrating SDG-aligned indicators within project frameworks, providing a replicable model for similar initiatives.

Carbon fibre-reinforced polymers (CFRPs) are a lightweight alternative solution for various applications due to their mechanical and structural properties. However, debonding at the fibre–matrix interface is an important failure mechanism in composite materials. Proposed solutions include using nano-scale reinforcements to strengthen and toughen structural composites. This study covers a comprehensive approach for evaluating occupational hazards during the sizing of 6k carbon fibres using multi-walled functionalized carbon nanotubes (MWCNTs) and few-layer graphene (FLG) at a pilot scale. Material hazard and exposure banding showed elevated risks of exposure to nanomaterials during the sizing process, while a ‘what-if’ process hazard analysis allowed for the evaluation of hazard control options against the hypothetical process failure scenarios of human error and utilities malfunctioning. On-site measurements of airborne particles highlighted that using MWCNTs or FLG as a sizing agent had negligible effects on the overall exposure potential, and higher micro-size particle concentrations were observed at the beginning of the process, while particle size distribution showcased high concentrations of particles below 50 nm. This analysis provides a thorough investigation of the risks and potential exposure to airborne hazardous substances during CF sizing while providing insights for the effective implementation of a safe-by-design strategy for designing targeted hazard control systems.

In modern manufacturing environments, pollution management is critical as exposure to harmful substances can cause serious health issues. This study presents a two-stage computational fluid dynamic (CFD) model to estimate the distribution of pollutants in indoor production spaces. In the first stage, the Reynolds-averaged Navier–Stokes (RANS) method was used to simulate airflow and temperature. In the second stage, the Lagrangian method was applied for particle tracing. The model was applied to a theoretical acrylonitrile butadiene styrene (ABS) filament 3D printing process to evaluate the factors affecting the distribution of ultrafine particles (30 nm). Key parameters such as ventilation system effects, the presence of cooling fans and the print bed, and nozzle temperatures were considered. The results show that the highest flow velocities (1.97 × 10−6 m/s to 3.38 m/s) occur near the ventilation system’s inlet and outlet, accompanied by regions of high turbulent kinetic energy (0.66 m2/s2). These conditions promote dynamic airflow, facilitating particulate removal by reducing stagnant zones prone to pollutant buildup. The effect of cooling fans and thermal sources was investigated, showing limited contribution on particle removal. These findings emphasize the importance of digital twins for better worker safety and air quality in 3D printing environments.

In the last few years, the materials research community has shown increased interest in Advanced Materials (AdMas) that are specifically designed to substitute the traditionally used materials, not only with a view to their sustainability, sourcing criticality, or scarcity, but also to maintaining or even enhancing their functionality and performance. The use of AdMas is particularly researched in sectors where the environmental impact of the traditional materials is substantial, in terms of waste production or resource consumption. Due to their novelty and potentially unpredictable impacts, and to add further value to their application, there is an increasing interest in the safety and sustainability of AdMas. In this context, a new 5-step Safe-and-Sustainable-by-Design (SSbD) framework was developed by the European Union, to support the (re-)design and development of novel materials. A guideline is presented for enforcing the (re-)design phase of the framework with paradigms to guide stakeholders and practically add value to the materials’ industry. The present manuscript analyzes the advances and challenges of the SSbD framework, showcasing its applicability and limitations and the added value compared to traditionally used assessment methodologies, to provide a comprehensive evaluation of the methodology and add value to the materials’ industry concerning safety and sustainability.

The project M2DESCO is directed at addressing new challenges for developing next-generation high-entropy-alloy-based multi-component green (free of toxic substances) and sustainable (rare earth free & minimum critical metal elements) coatings with predictable functionalities, performance and life - aiming at increasing wear resistance by 100%, corrosion/oxidation resistance by 50~60 %, and effectively reducing the criticality of coating materials by at least 70%. To achieve these goals, the project is to integrate artificial intelligence/machine learning AI/ML underpinned, highly effective and highly efficient Computational Modelling that is guided by a novel Safe and Sustainability by Design Framework and facilitated by high-throughput characterisations and evaluations, to speed up the material-design to coating-product development process (reducing the development cycle-time by 400~500%). At the same time, M2DESCO is to enable optimal alloy/material design and coating process optimisation for high efficiency and high quality, so to reduce the overall product manufacturing cost (due to use of the new tooling developed) by 20%. The advancement of M2DESCO will contribute significantly to combating the loss in EU region caused by corrosion and wear, to the enhancement of the global profile and leadership of the EU material modelling/research community, to strengthening of the innovation capability of the EU coating industry/business.

Airborne pollutants pose a significant threat in the occupational workplace resulting in adverse health effects. Within the Industry 4.0 environment, new systems and technologies have been investigated for risk management and as health and safety smart tools. The use of predictive algorithms via artificial intelligence (AI) and machine learning (ML) tools, real-time data exchange via the Internet of Things (IoT), cloud computing, and digital twin (DT) simulation provide innovative solutions for accident prevention and risk mitigation. Additionally, the use of smart sensors, wearable devices and virtual (VR) and augmented reality (AR) platforms can support the training of employees in safety practices and signal the alarming concentrations of airborne hazards, providing support in designing safety strategies and hazard control options. Current reviews outline the drawbacks and challenges of these technologies, including the elevated stress levels of employees, cyber-security, data handling, and privacy concerns, while highlighting limitations. Future research should focus on the ethics, policies, and regulatory aspects of these technologies. This perspective puts together the advances and challenges of Industry 4.0 innovations in terms of occupational safety and exposure assessment, aiding in understanding the full potential of these technologies and supporting their application in industrial manufacturing environments.

In the original publication [...]

With the green energy transition, the wind industry has grown rapidly in recent decades. Wind turbine blades (WTBs) are primarily manufactured from glass fibers and thermoset matrix composites. Considering their lifetime from 20 to 25 years, significant amounts of wind turbine components will eventually enter the global waste stream. Currently, recycling is not sufficiently optimized and commercially available. Other strategies, such as repurpose, are becoming relevant to divert components from waste streams. This research explores a pathway to sustainable repurposing of decommissioned WTBs. The concept of a tiny house constructed from the root section of a 5 MW/61.5 m WTB is presented (“5 MW house”). The deformations and stresses of the repurposed composite structures were investigated using a finite element analysis based on the three load cases, defined by (1) a combination of snow load and payload, (2) a combination of wind load and payload, and (3) a thermal stress analysis of a critical temperature distribution of the 5 MW house. Furthermore, a life cycle assessment (LCA) was conducted to evaluate the environmental impacts of the proposed concept. The numerical analysis results showed that the 5 MW house can withstand the applied loads, and that the deformations are within acceptable limits. A reduction of up to 97% in environmental impacts for most impact categories was calculated, compared to a wooden tiny house, whereas climate change, ozone depletion, and eutrophication potential were up to 3.7 times higher, mainly due to the weight and composition of the 5 MW house. The authors believe that the proposed concept may be a high-volume repurposed solution for large-scale WTB root sections.