Following an intensive development of new sensors and software Synthesites successfully demonstrated its inteligent manufacturing systems for the Industry 4.0 at three distinct industrial cases  within the ECOMISE project.       In the industrial demonstrators built at Bombardier Aerospace Belfast (wing  skin with autoclave), Hutchinson (suspension blade with RTM) and Airborne (tidal turbine blade with infusion) all the developed technologies such as intelligent process monitoring, real-time adjustment of process simulation, real-time process control have been successfully applied and verified. In the Bombardier demonstrator, 2 cureand 12 resin arrival sensors were installed at a wing-cover mould including all the wiring (of more than 15m long) and tested within their Wing Production Unit. The demonstrator was completely successful with all sensors and systems performing as expected while there was a real-time prediction of the on-going Tg for both cure sensors.

In the Hutchinson demonstrator (photo), several cure, resin arrival and Flowire sensors were installed in a RTM mould for the manufacturing of a gfrp thick automotive component. In more than 10 injections all sensors and real-time Tg prediction software recorded resin arrival times and cure indicating in real-time the on-going Tg and proposing control actions with respect to heating and cooling.

In the Airborne demonstrator, more than 20 cure, resin arrival, temperature and pressure sensors were installed for the manufacturing of a new 2m tidal blade. This was a cfrp part using aerospace grade epoxy, injected and cured in an oven. The use of the sensors helped to achieve 'first-time right' product while the online Tg prediction showed that a 50% speed-up with respect to the initial designed cure cycle duration was possible.