L4MS [TrySMART]

TrySMART project focused on automating the transportation of heavy manufacturing molds at TRYGONS facilities by using Autonomous Guided Vehicles (AGVs) and digitizing the entire process. In partnership with the Institute of Communication and Computer Systems (ICCS) and the National and Kapodistrian University of Athens, the project successfully designed and implemented a technological solution, validating the proof of concept.

The project also demonstrated the potential for full operational deployment, with 4-5 AGV kits functioning simultaneously. This automation not only streamlined the transportation process but also removed a physically demanding task from human operators, improving working conditions and operational efficiency at TRYGONS.

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​L4MS is a project funded by the Horizon 2020 Programme under grant agreement Nº 767642 — L4MS — H2020-IND-CE-2016-17/H2020-FOF-2017 (Grant Agreement).

StairwAI [AgRerTry]

The AgRerTry AI-driven solution, came as a natural extension of VirtFuse, is focusing on optimizing resin mix parameters for the infusion process using AI, while developing a scalable framework adaptable to similar applications. The AI model calculates optimal resin mix (catalyst and accelerator quantities) based on temperature and product type, visualizes the data through a dashboard, and includes functionality for scaling to new products outside the initial training dataset.

In collaboration with IthermAI, which developed and trained the AI model, TRYGONS handled the setup of monitoring equipment and collected production data from 50 infusions. The teams worked together on testing and validation to ensure the model effectively optimized the resin infusion process, improving both quality and production efficiency.

Change2Twin [ComProBotTwin]

As part of the Change2Twin Open call, the ComProBotTwin project introduced a digital twin solution for TRYGONS' gelcoating process. The purpose of this digital twin is to achieve a comprehensive, high-fidelity replication and monitoring of the complex gelcoating operation. By integrating advanced sensors and digital technologies, the system accurately tracks and analyzes the entire process, which is crucial for ensuring product quality. The solution’s predictive maintenance and early fault detection capabilities have minimized downtime and maintenance costs while enhancing product quality. Working conditions have also improved significantly by removing the need for employees to perform monitoring tasks in a challenging environment. The system also offers remote monitoring, giving operators full control of operations from any location.

This innovative solution has given us complete control of the gelcoating process, marking another step towards technology-driven production and laying the groundwork for further digitalization and efficiency gains.

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This project has received funding from the European Union’s Horizon 2020 research and innovation programme within the framework of the Change2Twin Project funded under grant agreement No 951956.

RESIST [Exofuse]

The ExoFuse project aims to optimize the resin curing process in composite manufacturing by utilizing the exothermic reaction of the resin-catalyst mixture instead of relying on external heat sources. A digital AI assistant continuously monitors the process in real time, precisely calculating the initial heat-shot required to trigger the chemical reaction.

This innovative approach enhances the efficiency of the polymerization process while reducing energy consumption, making it a more sustainable solution for composite production. ExoFuse represents a significant advancement in leveraging chemical reactions for energy-efficient manufacturing processes.

Kyklos 4.0 [VirtFuse]

VirtFuse is an advanced cloud-edge digital twin solution designed to monitor and optimize the Resin Vacuum Infusion Process (RVIP) in real time. Through a user-friendly web dashboard, operators can track the resin’s curing progress and receive actionable feedback throughout the process.

By integrating data from curing sensors, temperature measurements, and RGBT cameras, VirtFuse evaluates and assigns quality scores to each produced part. This immediate feedback enables real-time adjustments, driving continuous improvements in product quality. The system enhances process control and material efficiency while providing a comprehensive, visual overview of the entire infusion process, supporting informed decision-making and quality assurance.

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The VirtFuse has indirectly received funding from the European Union’s Horizon 2020 research and innovation action programme, via the KYKLOS 4.0 Open Call #2 issued and executed under the KYKLOS 4.0 project (Grant Agreement no. 872570).

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​Innobuyer [SprAI]

This project focuses on automating the gelcoat application process for large composite parts, such as yachts, automobile cabins, and wind turbine blades. The primary challenge is frequent spray tip blockages, which disrupt layup thickness, degrade product quality, and lead to costly repairs or scrapping, increasing production costs and material waste.

To address this, high-resolution cameras are installed at various angles, providing a constant, unobscured view of the spray beam. Advanced image processing techniques enable real-time blockage detection, allowing immediate corrective action. This approach enhances product quality, reduces material waste, and lowers production costs, improving both efficiency and sustainability..

Gemstone [AIvent]

As part of the AIvent project, an AI-driven industrial ventilation control system was developed to optimize energy usage by dynamically adjusting fan and heater operation based on real-time pollution levels and occupancy. This intelligent system has significantly reduced energy consumption while enhancing air quality and creating a safer, healthier work environment for employees.

AIvent’s core functions include adaptive ventilation control, precise temperature regulation, and automated environmental monitoring, setting a new benchmark for sustainable industrial practices. The implementation of this system not only reduces energy use but also improves working conditions, contributing to a more efficient and responsible production environment.

Prospects 5.0

The PROSPECTS 5.0 project is dedicated to advancing the adoption of Industry 5.0 principles, including human-centricity, sustainability, and resiliency. Its goal is to facilitate the transition to Industry 5.0 for SMEs, start-ups, and scale-ups across various industries. The project achieves these objectives by offering comprehensive reports, guidelines, measurement tools, and a collaborative platform to support businesses in embracing the next generation of industrial transformation.

Our digital transformation over the past few years with the adoption of cutting-edge technologies and commitment to aligning with Industry 5.0 principles made us a natural fit for this initiative. By participating in PROSPECTS 5.0, we continue to pursue our goal of creating a forward-thinking, sustainable, and human-centered manufacturing environment.

This innovative approach enhances the efficiency of the polymerization process while reducing energy consumption, making it a more sustainable solution for composite production. ExoFuse represents a significant advancement in leveraging chemical reactions for energy-efficient manufacturing processes.

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Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or European Health and Digital Executive Agency (HADEA). Neither the European Union nor the granting authority can be held responsible for them.