Surface texturing is an effective method to reduce friction without the need to change materials. In this study, surface textures were transferred to rubber samples in the form of dimples, using a novel laser surface texturing (LST)—based texturing during moulding (TDM) production process, developed within the European Project MouldTex. The rubber samples were used to experimentally determine texture-induced friction variations, although, due to the complexity of manufacturing, only a limited amount was available. The tribological friction measurements were hence combined with an artificial intelligence (AI) technique, i.e., Reduced Order Modelling (ROM). ROM allows obtaining a virtual representation of reality through a set of numerical strategies for problem simplification. The ROM model was created to predict the friction outcome under different operating conditions and to find optimised dimple parameters, i.e., depth, diameter and distance, for friction reduction. Moreover, the ROM model was used to evaluate the impact on friction when manufacturing deviations on dimple dimensions were observed. These results enable industrial producers to improve the quality of their products by finding optimised textures and controlling nominal surface texture tolerances prior to the rubber components production.

Micro-surface texturing of elastomeric seals is a validated method to improve the friction and wear characteristics of the seals. In this study, the injection process of high-viscosity elastomeric materials in moulds with wall microprotusions is evaluated. To this end, a novel CFD methodology is developed and implemented in OpenFOAM to address rubber flow behaviour at both microscale and macroscale. The first approach allows analyzing the flow perturbation induced by a particular surface texture and generate results to calculate an equivalent wall shear stress that is introduced into the macroscale case through reduced order modelling. The methodology is applied to simulate rubber injection in textured moulds in an academic case (straight pipe) and a real case (D-ring seal mould). In both cases, it is shown that textured walls do not increase the injection pressure and therefore the manufacturing process is not adversely affected.

To meet the European Green Deal targets, the construction sector must improve building thermal performance via advanced insulation systems. Eco-friendly sandwich panels offer a promising solution. Therefore, this work aims to develop and validate a new eco-friendly composite sandwich panel (basalt fibres and recycled extruded polystyrene) with enhanced multifunctionality for lightweight and energy-efficient building façades. Two panels were produced via vacuum infusion—a reference panel and a multifunctional panel incorporating phase change materials (PCMs) and silica aerogels (AGs). Their performance was evaluated through lab-based thermal and acoustic tests, numerical simulations, and on-site monitoring in a living laboratory. The test results from all methods were consistent. The PCM-AG panel showed 16% lower periodic thermal transmittance (0.16 W/(m²K) vs. 0.19 W/(m²K)) and a 92% longer time shift (4.26 h vs. 2.22 h), indicating improved thermal inertia. It also achieved a single-number sound insulation rating of 38 dB. These findings confirm the panel’s potential to reduce operational energy demand and support long-term climate goals.

Background: Micro-texturing is an increasingly used technique that aims at improving the functional behaviour of components during their useful life, and it is applied in different industrial manufacturing processes for different purposes, such as reducing friction on dynamic rubber seals for pneumatic equipment, among others. Micro-texturing is produced on polymer components by transfer from the mould and might critically increase the adhesion and friction between the moulded rubber part with the mould, provoking issues during demoulding, both on the mould itself and on the rubber part. The mould design, the coating release agent applied to the mould surface, and the operational parameters of the moulding/demoulding process, are fundamental aspects to avoid problems and guarantee a correct texture transfer during the demoulding process. Methods: In this work, the lack of knowledge about demoulding processes was addressed with an in-house test rig and a robust experimental procedure to measure demoulding forces (DFs) as well as the final quality of the moulded part, between thermoset polymers and moulds. After the characterization of several Sol-Gel coating formulations (inorganic; hybrid) the influence of several parameters was analysed experimentally, i.e.: Sol-Gel efficiency, texture effects, pattern geometry, roughness and material compound. Results: The results obtained from the experimental studies revealed that texture depth is the most critical geometrical parameter, showing high scatter among the selected compounds. Finally, the experimental results were used to compute a model through reduced order modelling (ROM) technique for the prediction of DFs. Conclusions: The characterization of DFs in a laboratory, with a specific device operated by a universal testing machine (UTM), provided valuable information that allows a fast and optimized introduction of texturing in rubber components. Selection of a novel Sol-Gel coating and the use of the ROM technique contributed to speed up implementation for mass production.

Textile-reinforced concrete (TRC) sandwich panels with lightweight cores are a promising solution for sustainable and slender building envelopes. However, their structural performance depends strongly on the shear connection between the outer shells. This study investigates the flexural behavior of TRC sandwich panels with glass fiber-reinforced polymer (GFRP) rod connectors under four-point bending. Three full-scale specimens were manufactured with high-performance concrete (HPC) face layers, an expanded polystyrene (EPS) core, and 12 mm GFRP rods as shear connectors. The panels were tested up to failure, with measurements of load–deflection behavior, crack development, and interlayer slip. Additionally, a linear-elastic finite element model was developed to complement the experimental campaign, capturing the global stiffness of the system and providing complementary insight into the internal stress distribution. The experimental results revealed stable load-bearing behavior with ductile post-cracking response. A degree of composite interaction of γ = 0.33 was obtained, indicating partially composite action. Slip measurements confirmed effective shear transfer by the GFRP connectors, while no brittle failure or connector rupture was observed. The numerical analysis confirmed the elastic response observed in the tests and highlighted the key role of the GFRP connectors in coupling the TRC shells, extending the interpretation beyond experimental results. Overall, the study demonstrates the potential of TRC sandwich panels with mechanical connectors as a safe and reliable structural solution.

Materials science is at the crossroad between fundamental and applied sciences. Whether enabling clean energy, next-generation computing, or advanced manufacturing, it shapes the tools we use and the systems we build. As our societies undergo rapid digital, environmental, and technological transitions, materials science becomes even more central. It's a space where innovation can respond to practical challenges while aligning with broader social values. In the European context, that means supporting sustainability, openness, and solidarity -while also strengthening competitiveness.This roadmap explores how digital tools-especially simulation, data science, and AI-are transforming materials research, in connection with the twin digital and energy transition. The digital transition refers to the widespread adoption of digital technologies and data-driven methods across sectors, while the green (or energy) transition focuses on shifting toward sustainable, lowcarbon energy systems-together forming what is often called the twin transition, a joint effort to make economies both smarter and more sustainable.The Roadmap outlines both the technical directions and the cultural shifts needed to make this transformation inclusive and effective. Chapters span from atomic-scale simulations to advanced experimentation, from reproducibility to intelligent optimization, and from institutional reform to education for the next generation.Importantly, this isn't a single viewpoint. The document brings together a wide range of voices: researchers from different disciplines, working across length and time scales. It includes early-career scientists and senior experts. Enabled by activities supported by European Cooperation in Science and Technology (COST), it reflects a commitment to gender and geographic diversity. This plurality doesn't just enrich the content-it makes the vision more robust and relevant.We hope this collection serves not just as a guide, but as an invitation to collaborate-across fields, sectors, and borders-as we reimagine the future of materials science in a digital age.