Tosca project

Manufacturing Processes and Digital Tools for More Sustainable Composite Aerostructures

Greener Flying: TOSCA Paves the Way for Sustainable Aircraft

The TOSCA project is leading the way toward more sustainable aviation by improving composite production efficiency and recyclability. With €4.5 million in funding from Horizon Europe, it brings together top research institutions and industry partners. By 2027, the project aims to develop solutions that will significantly reduce aviation's environmental impact.

The Challenge: Composite Recycling in Aerospace

Fiber-reinforced composites are crucial for lightweight aircraft but pose recycling challenges, with only 15% being reused while the rest is incinerated or landfilled. Additionally, current production methods generate excessive waste and CO₂ emissions. New technologies are required to improve sustainability without compromising performance.

Innovative Solutions: A Smarter, More Sustainable Processing Chain

TOSCA is developing a new composite processing chain using epoxy vitrimer resin, an advanced material that retains traditional composites’ strength while being repairable and recyclable. This innovation allows materials to be reshaped and reused, enabling a circular economy. The project also integrates automation and digital monitoring to create a zero-defect manufacturing process.

Partner Contributions: A Collaborative Effort for Sustainability

TOSCA unites European research institutions and industry partners, each contributing expertise to tackle composite manufacturing and recycling challenges. PROFACTOR leads automation and AI-driven inspections, while other partners focus on specialized developments. GMI Aero is developing smart monitoring and repair adaptation technologies to optimize composite lifecycle management.

By the end of the project, the TOSCA consortium aims to deliver a fully optimized, sustainable manufacturing process that will shape the future of aerospace composites—reducing waste, lowering emissions and increasing Europe's strategic autonomy in advanced materials. Stay tuned as we take the next steps towards a more sustainable aerospace industry.

Learn more about TOSCA through the Project Coordinator /

Christian Eitzinger, Christian.Eitzinger@profactor.at

Or visit Research and Development GMI Aero