Projects

Welcome to the list of our research group’s projects in the field of microwaves. Our team of researchers is dedicated to advancing knowledge in this area and has undertaken several projects to achieve this goal. We hope that you find our work informative and engaging, and we welcome your feedback and suggestions

PRINTWAVE

Innovating 3D Food Printing with Simultaneous Microwave Processing

3D printing technology has recently attracted the attention of the food sector by enabling the design of customized foods in terms of dimensional, sensory, and nutritional properties. Three-dimensional food printing (3DFP) is an innovative additive manufacturing (AM) application that uses food 3D printers with edible inks. Unlike conventional 3D printers that use plastics and metals, 3DFPs use food-based inks that can be combined in a variety of ways. Most 3DFPs do not require heat to process food, as they use vegetable pasta, sugar, or chocolate, eliminating the need for pre-consumption heating. However, some food matrices based on vegetables, proteins, or bread doughs require post-printing heat treatment. In this context, a project arises that proposes the integration of a focused microwave (MW) heating mechanism in food 3D printers, allowing more precise spatial control of heat during printing.

This innovation would make it easier to create complex foods with more ingredients and integrate multiple food elements into a single 3D object. Microwave technology is presented as an efficient and ecological alternative for the rapid and homogeneous heating of food, being known for its positive economic and environmental impact. The project, led by a multidisciplinary team from the Universitat Politècnica de València, the Institute of Food Engineering (FoodUPV), and the ITACA Institute (Institute for the Applications of Advanced Information and Communication Technologies), seeks to develop equipment that allows layer-by-layer cooking of food in a targeted and controlled manner through the combination of 3D printing and microwave technologies.

The collaboration between these groups has already resulted in the filing of a joint patent (P202330889) for this equipment. One of the highlights of the project is its approach to sustainability and circularity in the food industry. The use of a microwave heating mechanism and the development of customized food inks from by-products or surpluses from the food industry represent a significant advance in resource management. Not only does this strategy reduce waste, but it also adds value to materials that would otherwise be discarded, contributing to circularity by closing the life cycle of these components.

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i3DAM

Innovation in Personalized and Sustainable Foods: 3D Printer with MW Integration

The I3DAM project aims to develop a 3D food printer with integrated microwave thermal processing for on-site food cooking, layer-by-layer, during printing, in an environment similar to a real-world setting. Technical and commercial feasibility will be demonstrated with a prototype certified for electromagnetic emissions and food safety, capable of printing and cooking foods based on new food inks developed for this application.

The problem of sustainable food supply at a global level is one of the most critical and urgent challenges of the 21st century. The growing global population, projected to reach 9.7 billion by 2050, along with the limitation of natural resources and the effects of climate change, has placed unprecedented pressure on global food systems. Food production and distribution must evolve to become more efficient, equitable, and environmentally friendly.

In this context, 3D food printing arises as a innovative technology with the potential to radically transform the way of producing and consuming food, introducing culinary innovations, improving personalized nutrition and promoting sustainability.

Recently (October 31, 2023), the project leaders, researchers from the ITACA Institute and the Food Engineering Institute (FoodUPV) at UPV, patented (P202330889) an innovative device that combines 3D printing and microwave cooking, capable of thermally process food, layer-by-layer in a targeted and controlled manner, all within the same printing device, addressing some of the most relevant challenges in these techniques.

This patent is the first for this process, during which it is expected that additional patents from the same family will be added as this innovative technology continues being developed.

 

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FLEXHYON

Flexible hybrid electrical systems for sustainable process intensification on-demand and where required

Recognizing the significance of energy efficiency in industry and carbon emissions reduction, FLEXHYON is proposing a clever combination of alternative fully electrified heating systems (microwave, heat pumps, ultrasound) to tackle three specific industrial processes: ultrafast drying of compact material, drying of granular materials and distillation/extraction of ground material to address their urgent need to transition from fossil energy to renewable and low-carbon energy sources.

Three optimized prototypes will be built and demonstrated in 3 industrial environments: ceramics, feed production, biomass. The quality and economic impact of the developments will be evaluated using LCA and LCC; environmental and technical performances, health protection, safety will be demonstrated and validated. Sound market strategies will be developed, giving clear indications on scalability, transferability and replicability across different industrial sectors, commercialization and deployment will be achieved through development and validation of set of business models for the 3 business cases.

The FLEXHYON solutions will exhibit significantly higher energy efficiency in comparison to traditional fossil fuel-based heating technologies, therefore leading to a reduction in GHG emissions, maximizing primary energy savings, and enabling higher production flexibility (e.g. production on-demand, production on-site). Their scalability (upscaling, downscaling) will allow to better follow market demand and enable leaner production paradigms.”

 

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AI-MetPro

Precise Control of Singular Microwave Field Distributions through AI-Calibrated Simulations for Advanced Processing in Metallurgy

Increasing environmental and security restrictions in the automotive sector are forcing the industry to shift from steel towards the development of more sustainable and cost-efficient light alloys manufacturing technologies for structural components (i.e. aluminium and magnesium). However, these manufacturing technologies nowadays still incur in high production costs. Therefore, a new paradigm in metal parts manufacturing is targeted that will allow implementing lightweight metal components with improved performance, while reducing energy and resource consumption, able to replace current steel structural components in industrial mass production lines.

Die Casting (DC) is nowadays a recognized technology for the production of aluminium parts, especially Aluminium components used in the transport industry. To improve their performance and extend their durability, DC produced parts can be densified with High Isostatic Pressure (HIP). The possibility of applying microwave technology to perform this heat treatment has been already demonstrated in a previous project with the same partners (HIPPERWAVES), leading to important energy savings and reduced processing times.

 

However, the quality of the produced parts is dramatically dependent on the temperature profile achieved by the metal parts during the heating process. This project proposes a ground-breaking Artificial Intelligence-based tool able to tailor the temperature profiles inside the microwave reactor. The method relies on the development of accurate multiphysic 3D models that include electromagnetic and thermal equations and provide the basis for the AI-based optimization of the desired thermal profiles. This novel system would be the basis to produce metal parts with exceptional properties, due to the ultrafast, volumetric and optimized microwave heating process applied to metal powders.

Although results from the state of the art proved that metallic powdered materials can be efficiently heated by microwaves, the developments proposed in this project will suppose a technological breakthrough supported in the ambitious undertaking of the following challenges: (1) development of new 3D multiphysic models including strategies for modifying the electric field distribution; (2) approaches to tailor specific microwave heating thermal profiles from AI-based machine-learning processes; (3) adequate designs to ensure proper interaction between microwaves and target materials; (4) fully operative control routines and protocols linked to products quality and security aspects.

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HIPPERWAVES

High Performance and Cost-Effective Microwave Processing of Metal Parts with Ultra High Isostatic Pressing

The automotive industry is under increasing pressure from environmental and security regulations, driving a crucial shift from traditional steel to more sustainable and cost-efficient light alloys such as aluminium and magnesium. Despite their advantages, the current manufacturing technologies for these materials still face high production costs.

Die Casting (DC) is a well-established technology for producing aluminium parts, particularly for the transport industry. High Isostatic Pressure (HIP) can be applied to DC-produced parts for densification to enhance the performance and durability of these components.

The HIPPERWAVES project aims for a pioneering technology that combines HIP processes with an advanced microwave reactor (MW-HIP). This innovative system promises an efficient and rapid method for producing metal parts with exceptional properties, leveraging the ultrafast and volumetric nature of microwave heating applied to metal powders.

The microwave technology developed in the HIPPERWAVES project will revolutionize the manufacturing and post-processing of metal components, offering unprecedented superior properties. This advancement will significantly enhance the efficiency of HIP processes, resulting in substantial cost reductions. Integrating this technological leap will dramatically streamline the production process, leading to significant material and energy savings and improved component quality.

Preliminary laboratory trials indicate that the application of microwave energy in the HIP process can reduce processing time dramatically, potentially increasing productivity by an order of magnitude and lowering associated costs by a factor of ten.

The HIPPERWAVES project is supported by a strong partnership between two leading entities. The Microwave Division of the ITACA Insitute of the Universitat Politécnica de València (ITACA-DIMAS UPV) brings unparalleled expertise in microwave technology, while ROVALMA S.A., an R&D-intensive SME, excels in the development of steels and other alloys. This interdisciplinary collaboration integrates extensive experience in materials science, mechanics, and industrial design, ensuring the project’s success through their combined expertise and resources.

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