[ Circularity ]
[ Circularity ]
• CO 2 emissions reductions of 25-50 %
• Material waste reduction of 25-30 %
• Component weight reduction of up to 30 %
• Defect reduction of 50-80 %
• Fatigue life extension of 50-80 % in hydroturbine components
These targets reflect a broader objective: to reduce dependence on virgin raw materials while maintaining, or improving, component performance. For metallic systems, this translates into lower reliance on mined ores, reduced energy consumption, and a measurable decrease in greenhouse gas emissions.
“ How do we improve the use of secondary materials in additive manufacturing?”
Tackling variability in recycled stainless A central focus of the project is the use of recycled stainless steel, alongside aluminium alloys and fibre-reinforced polymers. While stainless steel is inherently well-suited to recycling, variability in feedstock- such as fluctuations in chemical composition, impurity levels, and powder characteristics- has historically limited its use in high-performance applications. GEAR-UP addresses these issues through a combination of digital and process innovations, including:
• AI-powered life-cycle assessment tools for quantifying environmental impact at the component level
• Advanced material and process simulations that account for variability in recycled feedstock
• Structured data models and knowledge graphs to improve traceability across the product lifecycle
• Simulation-driven design methodologies to optimise components prior to production
Together, these tools enable manufacturers to better predict material behaviour, reduce process uncertainty, and ensure consistent performance when working with secondary raw materials.
Industrial validation across key applications The project demonstrates its approach through a series of industrial use cases that highlight the practical potential of circular manufacturing. Hydropower turbines – additive repair using stainless steel- In one of the most relevant applications for the stainless steel sector, Pelton turbine components are repaired using laser-based directed energy deposition( DED-LB / W) with recycled 13-4 stainless steel. Rather than replacing entire forged components, additive repair enables targeted material deposition, extending component lifetimes by 50-80 % while reducing material consumption by 80-95 %. The same process can also be applied to the manufacture of new components, offering flexibility in both maintenance and production strategies. Robotic grippers – recycled aluminium via PBF-LB- Robotic grippers, traditionally produced from titanium, are being manufactured using recycled AlSi10Mg aluminium through laserbased powder bed fusion( PBF-LB). While slightly bulkier than their titanium counterparts, the components maintain full functional performance, demonstrating a viable lower-cost and lower-impact alternative. High-performance composites – recycled polymer systems- Recycled PET is converted into filament reinforced with carbon fibres and titanium dioxide nanoparticles. These materials are used to produce components such as cogwheels for electric snowmobiles, combining low weight with resistance to wear, UV exposure, moisture, and extreme temperatures.
Overcoming process and material challenges Despite the progress achieved, several technical challenges remain. These include:
• Control of impurities in recycled feedstock
• Managing powder particle size distribution in additive processes
• Addressing minor chemical variations that can affect performance
By integrating simulation tools and realtime data analysis, GEAR-UP provides a framework for mitigating these risks and improving process reliability.
Building capability across the value chain Beyond technology development, GEAR-UP places strong emphasis on skills and workforce development. The project includes dedicated training programmes designed to upskill engineers and operators in areas such as:
• Additive manufacturing processes and standards
• Simulation and digital engineering
• AI-driven life-cycle assessment
• Circular design and system integration
This is critical to enabling wider adoption, as the successful implementation of circular manufacturing depends not only on materials and processes, but also on the capabilities of the workforce.
Enabling industrial-scale circularity GEAR-UP delivers value across the manufacturing ecosystem. OEMs benefit from longer-lasting, higherquality components with reduced lifecycle costs. Technology providers gain access to advanced tools for flexible and efficient production. Research institutions can build on validated datasets, while policymakers receive tangible evidence supporting the industrial viability of circular manufacturing. For the stainless steel industry in particular, the project reinforces a key point: recycled materials are not a compromise, but a viable pathway to maintaining performance while improving sustainability. By combining digital tools, advanced manufacturing, and validated industrial use cases, GEAR-UP demonstrates that circular manufacturing can be implemented at scale, without sacrificing quality or reliability.
For more information, visit gearup-project. eu The GEAR-UP project has received funding from the European Union’ s Horizon Europe research and innovation programme under grant agreement No. 101178484
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