Eureka Lightweighting Call 2025

15 May – 23 Oct 2025

Project cooperationUpdated on 30 May 2025

Closed-loop Additive Manufacturing of Lightweight Boron-alloyed Lattice Structures from High-tech Scrap: A Sustainable Path to Circular Metallurgy

Ganna Polishko

Head of Department at E.O. Paton Electric Welding Institute

Kyiv, Ukraine

About

This project aims to establish a closed-loop value chain for the production of lightweight lattice structures made from boron-alloyed high-strength steels. Utilizing advanced additive manufacturing technologies—Selective Laser Melting (SLM) and Plasma Arc Direct Metal Deposition (PAD)—the project focuses on processing high-tech industrial scrap sourced from end-of-life components in the aerospace, energy, and defence sectors.

The core innovation lies in integrating the recycling of boron-containing steels with additive manufacturing to create high-performance, application-specific lattice structures. These structures are optimized for use in extreme environments where properties such as energy absorption, heat resistance, and structural integrity are critical.

The process chain encompasses several key stages:

  • Recycling and recovery of valuable alloying elements from complex scrap;

  • Production of metal powders via inert gas atomization;

  • Digital design optimization using digital twins and topology optimization;

  • Fabrication of final parts via AM technologies (SLM & PAD).

By closing the material loop and valorizing high-value scrap, the project enhances sustainability, reduces CO₂ emissions, and supports the transition to a circular economy in advanced manufacturing sectors.

Stage

  • Drafting - writing the project proposal

Topic

  • Optimisation of resource and energy efficiency
  • Bolster lightweight integration
  • Recycling of lightweight materials
  • Joining technology in multi material design
  • Additive Manufacturing

Type

  • Project idea seeking partner(s)

Organisation

E.O. Paton Electric Welding Institute

R&D Institution

Kyiv, Ukraine

Similar opportunities