Use case 01
Fire protective helmet
A hybrid-manufactured helmet shell demonstrating deep-drawn recycled titanium sheet for personal protective equipment.
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Overview
Horizon Europe · Innovation Action · N° 101294194
A circular, energy-efficient value chain for European titanium
EMPowerMet turns titanium swarf and end-of-life components into high-performance industrial parts, without relying on imported primary titanium.
Overview
Rethinking titanium manufacturing, from swarf to finished part
EMPowerMet project (Electric & Mechanical Power for Metal Manufacturing) is a Horizon Europe Innovation Action focused on transforming the way titanium components are manufactured in Europe. The project addresses Europe's dependence on imported primary titanium by creating a fully circular, energy-efficient value chain based on recycled titanium resources. Using advanced solid-state recycling technologies, including FAST and CONFORM™, EMPowerMet converts titanium swarf and end-of-life components into high-performance semi-finished products such as sheets and wires. These are further processed using deep drawing, wire-arc additive manufacturing and inductive heat treatment to produce high-value industrial components.
The project supports Europe's Green Deal and industrial transition by reducing greenhouse gas emissions, improving resource efficiency, minimising manufacturing waste and strengthening the resilience of European supply chains for critical raw materials.
Circular by design
A fully circular value chain built on recycled titanium swarf and end-of-life components, not imported raw material.
Solid-state recycling
FAST and CONFORM™ technologies convert titanium waste directly into sheets and wires with far less energy.
Aligned with the Green Deal
Lower emissions, less waste, and a more resilient European supply chain for critical raw materials.
Objectives
Six goals driving the project forward
Circular value chain
Establish a fully circular titanium manufacturing value chain based on secondary raw materials.
Lower environmental footprint
Reduce the environmental footprint of titanium processing through innovative manufacturing technologies.
Energy-efficient processes
Demonstrate energy-efficient solid-state recycling and advanced forming processes.
Validated manufacturing routes
Validate new manufacturing routes through industrial demonstrators.
Strategic autonomy
Strengthen Europe's strategic autonomy in critical raw materials.
Sustainable adoption
Promote sustainable manufacturing practices for future industrial adoption.
Impact
Industrial, environmental and economic benefits
EMPowerMet is expected to deliver significant benefits across three dimensions, strengthening European manufacturing while reducing its environmental cost.
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Energy savings vs. primary route
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Recycled titanium content
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Lower CO₂e vs. conventional
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Target buy-to-fly ratio (vs. 5.7)
Industrial
Improves the competitiveness of European manufacturers by providing reliable access to recycled titanium and advanced production technologies.
Environmental
Reduces energy consumption, greenhouse gas emissions and material waste while promoting circular economy principles.
Economic
Strengthens European resilience against supply-chain disruptions and supports the transition towards sustainable, resource-efficient manufacturing.
Implementation
A 36-month collaborative programme
The project is implemented over 36 months through a collaborative programme of 15 partners across 7 European countries, spanning research organisations, universities and industrial partners. Three industrial demonstrators will validate the developed technologies at TRL7.
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Months
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Demonstrators
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Partners
- WP1: Project management and coordination
- WP2: Technical requirements and process efficiency
- WP3: Scale-up of process technologies and materials
- WP4: Fabrication of semi-finished products
- WP5: Fabrication of demonstration objects
- WP6: Benchmarking (environmental, economic, circularity)
- WP7: Communication, dissemination and exploitation
Innovation
One integrated circular production chain
EMPowerMet combines several innovative manufacturing technologies within one integrated circular production chain, accelerating the adoption of sustainable titanium manufacturing and contributing to Europe's leadership in clean industrial technologies.
Solid-state titanium recycling
Converts titanium swarf and end-of-life components directly into semi-finished products, skipping energy-intensive melting.
Electrically-driven manufacturing
Electrically driven processes significantly reduce energy demand compared with conventional titanium production.
Hybrid production methods
Deep drawing, wire-based directed energy deposition (waDED) and inductive heat treatment combine to form high-value components.
Demonstrators
Three industrial demonstrators, validated at TRL7
EMPowerMet's process chain is validated against three real-world components made from 100% recycled titanium, proving the technology works where it matters most, in-service, under real industrial conditions.
Use case 01
Use case 02
Space landing gear structures
Two high-performance structural components manufactured from recycled Ti-5553, built for demanding aerospace loads.
Use case 03
Aeroplane service port
A hybrid-manufactured aircraft service port panel, combining waDED and inductive stress-relief treatment.
Follow EMPowerMet's progress toward TRL validation
Get project updates, consortium news, and demonstrator milestones as they happen.
