Sustainable Manufacturing of Functional Ceramics for Europe’s Net-Zero Industry Energy Devices

SuMaCer will deliver sustainable, first‑time‑right manufacturing of functional ceramics for Net‑Zero Energy Industry devices by integrating stereolithography (SLA), ceramic inkjet printing (CIP) and HiPIMS‑PVD with Zero‑Defect Manufacturing (ZDM), advanced modelling and a Digital Product Passport (DPP) backbone using open interfaces (OPC‑UA, MQTT, REST). Three industrial‑scale MVPs validate market relevance: (i) a 2 kW high‑efficiency SOFC stack; (ii) a 3.5 kW ultra‑compact SOEC stack for high‑pressure operation; and (iii) a 1.5 kWh metal‑supported sodium battery (MS‑NaB) module. Demonstrations on pilot lines provided by Solydera, H2B2/IREC (Merce‑Lab) and LiNa ensure validation under relevant industrial conditions; manufacturing routes will reach TRL 7 and MVPs TRL 6–7.Acceptance is underpinned by quantified KPIs: defect rate <5%, first‑time‑right ≥95%, energy savings ≥70%, material‑waste reduction ≥80%; CRM reduction is enabled via cobalt‑free compositions and thin‑film barrier/protective layers. Innovative metrology, a decision‑support system and dynamic scheduling implement Detect‑Predict‑Prevent‑Repair ZDM loops for faster ramp‑up, higher OEE and lower scrap. Eco‑design, LCA/LCC and recycling pathways (≥50% recovery for key materials) embed circularity from the outset. Standardisation actions de‑risk certification and foster EU‑wide uptake and interoperability across equipment vendors and SMEs. Fully aligned with the Made in Europe Partnership and the call’s focus on advanced discrete manufacturing for strategic Net‑Zero technologies (batteries, electrolysers, fuel cells), SuMaCer strengthens European industrial sovereignty, reducing strategic dependencies, building high‑value skills and enabling sustainable manufacturing leadership, while providing a clear exploitation path towards the creation of a joint-venture for the market uptake through industrial pilots and supply‑chain partnerships.