Projects and Collaborations

The LabCom DISC-AER (2025–2030) project is a collaboration between the Mechanics and Proceeded of Development (MPE) department at Mines Saint-Étienne and the Saint-Étienne-based start-up EENUEE, which specialises in electric aviation. Supported by the French National Research Agency (ANR) as part of the LabCom 2024 programme, this joint laboratory aims to develop a 19-seat electric regional aircraft, named GEN-ee, designed with an innovative “flying wing” configuration (Blended-Wing-Body).

Challenges and objectives

The project brings together five teacher-researchers from the MPE department to address issues related to high-performance composites. Structural weight reduction is a crucial challenge for electric aviation, where reducing weight helps optimise range and energy efficiency. In this context, the researchers are working on:

• Use of next-generation composite materials
  Replacing traditional metal components with advanced composites, while ensuring optimal mechanical performance.
• Modular design and manufacturing of aerostructures
  Developing methods to reduce the tooling required, thereby facilitating production and maintenance.
• Low-energy manufacturing implementation
  Optimising manufacturing processes so they can be carried out at room temperature, thereby reducing energy consumption.
• Simplified assembly and disassembly
  Designing structures that enable easy repair and autogenous welding, improving the aircraft’s durability and maintenance.
• Recyclability and reuse of materials
  Ensuring that the resins and fibres used are recyclable, thereby contributing to the project’s environmental sustainability.

Impact and outlook

The GEN-ee “flying wing” configuration is expected to improve aerodynamic performance and reduce energy consumption by 40%. The LabCom DISC-AER project aims to position EENUEE as a key player in electric air transport in France and Europe. It also contributes to efforts to decarbonise the aeronautics sector by exploring technologies that could be applied to future generations of regional aircraft.

Through this collaboration, the MPE department strengthens its expertise in composites and lightweight structures, consolidating its role in developing the materials of the future for more sustainable aviation.

The research programme, with a budget of €2 million over the 2024–2029 period, also includes significant equipment investments and the completion of four PhD theses, three of which will be under Industrial Agreements for Training through Research (CIFRE).

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Experimental and numerical characterisation of liquid infusion manufacturing of flax composites: from local phenomena to induced properties

The project, involving five teacher-researchers from the Mechanics and Proceeded of Development department, aims to deepen understanding of manufacturing processes for flax-fibre biocomposites by combining experimental and numerical approaches.

Project objectives

• Experimental characterisation: Studying the behaviour of flax-fibre reinforcements during resin infusion, analysing impregnation at different scales, from the individual fibre to the complete composite structure.
• Numerical modelling: Developing stochastic finite element models to simulate multiscale flows in bio-based fibrous media, enabling prediction of the final properties of composites based on manufacturing parameters.

Methodology

The project adopts an integrated approach, combining in-depth experimental testing and advanced numerical simulations. Two PhD theses are planned: one focused on the experimental characterisation of flax-fibre reinforcements during resin infusion, and the other on numerical modelling of flows in these fibrous media. A postdoctoral position will also strengthen the team to further develop this research.

Challenges and outlook

Flax-fibre composites offer significant advantages in terms of lightness, renewability and mechanical performance. However, the natural variability of flax fibres and the complexity of impregnation processes pose challenges in ensuring optimal mechanical properties and consistent quality of the parts produced. The LINEN project aims to overcome these barriers by providing characterisation and modelling tools to optimise manufacturing processes and ensure the reliability of biocomposite structures.

By addressing these challenges, the LINEN project will contribute to advancing knowledge in the field of biocomposites and support the development of more sustainable materials for a wide range of industrial applications.

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Sintering and biodegradation of carbonated hydroxyapatite ceramics for the reconstruction of large bone defects.

Launched at the end of 2021, this ANR “Young Female Researchers and Young Researchers” project, led by a teacher-researcher from the CIS centre, also involves the MPE department as a partner, contributing its expertise in sintering.

Project objectives

SiBio aims to develop and study the biodegradation potential of customised bioceramics based on carbonated hydroxyapatite (CHA) with a porous network featuring optimised surface curvature, intended for the treatment of critical-size bone defects. A specific architecture containing gyroid-type geometries, known to promote the rapid development of mature bone, will be studied.

Methodology

Developing CHA implants requires a CO₂-rich sintering atmosphere to stabilise the phase up to a temperature that enables densification. Sintering is therefore a crucial step to ensure the composition and final mechanical quality of the parts and, consequently, their biological properties. The project includes an in-depth study of reactive sintering of CHA parts under a mixed atmosphere in order to control the microstructure and final chemistry.

Partnership with the MPE department

The Materials and Proceeded of Development department contributes its expertise in sintering, helping to develop optimised protocols for densifying carbonated hydroxyapatite ceramics. This collaboration aims to ensure that the implants developed have the mechanical and biological properties required for the reconstruction of large bone defects.

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European Joint Programme on Radioactive Waste Management

The European EURAD-2 project is a collaborative initiative aimed at deepening knowledge and developing safe solutions for radioactive waste management in Europe. Launched in October 2024, this programme follows the first EURAD partnership (2019–2024) and introduces new research themes, such as the impact of climate change on waste management and the performance of covers for near-surface disposal.

Within EURAD-2, two teacher-researchers and a research engineer from the Mechanics and Proceeded of Development department are involved in a specific project on the sealing of radioactive waste containers. This project aims to propose innovative solutions using a microwave source to improve the sealing process.

The use of microwaves in container sealing offers several advantages, including controlled and localised heating, enabling optimisation of the properties of the materials used for sealing. This innovative approach builds on previous research, such as the microwave-heating assembly process at moderate temperature of an alumino-silicate ceramic material for overpacks for radioactive waste.

The MPE department’s participation in this project reflects its expertise in developing advanced processes and its commitment to contributing to sustainable solutions for radioactive waste management.

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