Duration: 20 months
The European space and semiconductor industries face converging strategic challenges: heavy reliance on imported high-purity materials, growing volumes of end-of-life (EOL) silicon-rich waste, and the urgent need for sustainable, high-performance materials tailored for demanding space applications. Silicon carbide (SiC), owing to its superior thermal, mechanical, and electronic properties, is a critical enabler of next-generation space systems. Yet, current SiC supply chains remain fragile, with virtually no high-value recycling or upcycling strategies in place.
ReSiCle propose a platform to address this gap by converting EOL silicon-rich waste streams (e.g., end-of-life photovoltaic modules) into high-performance SiC powders suitable for additive manufacturing (AM). The overarching goal is to establish a waste-to-performance materials pathway structured around 3 specific objectives (SOs):
SO1: develop a novel conversion route to transform waste silicon into SiC powders through mechanochemical synthesis (e.g., ball milling) followed by plasma-assisted spheroidization. This approach will allow precise control over particle size distribution, morphology, and phase composition.
SO2: assess the SiC powders for their flowability, thermal stability, and printability using Laser Powder Bed Fusion (LPBF)—a scalable AM technique for producing complex components. We will optimize process parameters to enable the fabrication of mechanically robust space-relevant parts, such as thermal protection tiles.
SO3: characteriz and proof of concept: Printed components will undergo mechanical and thermal characterization to assess phase purity, microstructural integrity, and performance. A proof-of-concept demonstration will validate the suitability of upcycled SiC parts for space applications.
By establishing the scientific and technological foundations of this circular materials platform, ReSiCle will open new avenues for sustainable material solutions in the European space ecosystem.
