New centre of excellence for energy-efficient anti-icing technologies

As part of the NEXUS project, the Warsaw University of Technology (Faculty of Materials Science and Engineering) will develop competences in the field of modern materials and systems for preventing icing of composite structures. The aim of the NEXUS project is to establish a Centre of Excellence strengthening the innovation potential of the Polish research ecosystem created by the TECHNOLOGY PARTNERS Foundation for Technological Partnership and Warsaw University of Technology (Faculty of Materials Science and Engineering). The Centre will focus on the development of hybrid anti-icing systems with increased energy efficiency.

"The project will combine research, training, workshops and staff exchanges, creating a competence centre for the development of next-generation technologies. One of the most important results of the undertaking will be the development of a technology demonstrator using innovative, multifunctional hybrid anti-icing systems integrating active heating solutions based on thermoplastic fibres with conductive nanoparticles with modern anti-icing coatings. The solutions developed may find applications, among others, in small aircraft, wind turbine blades and civil infrastructure, contributing to increasing the safety and energy efficiency of these systems by preventing ice accumulation," explains Professor Anna Boczkowska from the Faculty of Materials Science and Engineering, project leader on behalf of WUT.

The specific objectives of the project include:

1. Conducting joint research going beyond the current state of the art in the field of sustainable, multifunctional hybrid systems for energy-efficient ice prevention.
2. Establishing lasting cooperation networks between experienced and young researchers from different scientific institutions.
3. Conducting innovative training as part of 5 workshops, with particular emphasis on young researchers.
4. Strengthening research management capacities and administrative skills, including project writing and administration.
5. Raising the research profile and international recognition of the Polish partners.

The project is divided into 6 tasks, with the research component being carried out under Task 1 for 34 months. In addition to joint publications and conference presentations, the outcome of the research will be a technology demonstrator based on NACA0012 aerodynamic profiles, using an experimentally verified hybrid configuration of two innovative active anti-icing heating systems – one with conductive circuits produced using 3D printing and the other with extruded thermoplastic fibres – and enhanced with a modified icephobic coating.

International cooperation of researchers

The consortium implementing the project consists of the TECHNOLOGY PARTNERS Foundation for Technological Partnership (Poland), which is the project coordinator, Warsaw University of Technology – Faculty of Materials Science and Engineering, the Fraunhofer Institute for Applied Polymer Research IAP (Germany), and the Institute of Polymers, Composites and Biomaterials of CNR (Italy).

The combination of the experience of the partners from Germany and Italy and access to advanced research infrastructure will make it possible to create a lasting network of scientific cooperation between Polish institutions and recognised European research centres. An important part of the project will also be the development of researchers’ competences through the organisation of workshops, training sessions and short-term research stays for experienced and young researchers. Strengthening competences in research management and the preparation of international projects through coaching and specialised training is also planned.

Previous cooperation between the Technology Partners Foundation and the Faculty of Materials Science and Engineering has shown that the introduction of di- and trifunctional spheroclays into various coatings, as well as the use of laser texturing, makes it possible to effectively increase hydrophobicity and reduce icing of composite structures. The research proposed in the NEXUS project aims to go beyond the current state of the art by developing mechanisms preventing icing – both passive (coatings) and active (heating) – integrated into a single hybrid technical system. The main concept assumes combining controlled surface wettability, laser-textured hierarchical morphology and Joule heating (caused by the flow of electric current) within sustainable polymer matrices, which will make it possible to obtain coatings that both delay ice formation and actively remove it when necessary. Such an approach enables efficient Joule heating at low voltage, significantly reducing energy consumption during ice removal processes.

"Each partner brings complementary expertise in the field of functional coatings and heating systems, offering unique approaches to hybrid active-passive anti-icing technologies and their testing – capabilities that the other partner institutions do not have. As a result, cooperation within the research component will contribute to raising the level of scientific excellence in all participating institutions and research teams," emphasises Prof. Boczkowska.

The Technology Partners Foundation contributes experience in the production of thermoplastic heating fibres. The Warsaw University of Technology, specifically the Faculty of Materials Science and Engineering, offers advanced capabilities for shaping surface properties through laser texturing and multiscale structural characterisation, including research on icephobic and hydrophobic coatings, while the Institute from Italy has experience in the development, modification and application of coatings used in the production of composite components, and the Fraunhofer Institute has many years of experience in the field of heating systems manufactured using 3D printing. Laser texturing will be carried out at the Faculty of Materials Science and Engineering by Anna Łabęda, MSc, who is working on this subject as part of her doctoral research.

The team from the Warsaw University of Technology is headed by Prof. Anna Boczkowska from the Faculty of Materials Science and Engineering. Members of her Polymer Composites research group, consisting of 6 experienced researchers and 8 PhD students, will participate in the project. This is another project under the TWINNING programme implemented by Prof. Boczkowska’s team. The previous COMP-ECO project, Strengthening Mazovian multifunctional composite ecosystem through a holistic approach and a strategic alliance with European leaders, completed in December 2025, made it possible to establish lasting cooperation and numerous research stays for young researchers and PhD students at such renowned universities as TU Delft and TU Dresden. It was as a result of this project that the idea emerged to use thermoplastic fibres containing carbon nanotubes, produced by the team from the Faculty of Materials Science and Engineering, as active de-icing systems integrated into the composite structure. Combined with the topic of hydro- and icephobic coatings developed for 10 years by Rafał Kozera, PhD, and Bartłomiej Przybyszewski, PhD, members of the Polymer Composites team, this makes it possible to create hybrid systems that will be investigated in the NEXUS project.

The Warsaw University of Technology team hopes for fruitful cooperation within the project and further development of competences, as well as joint research projects in the future. The most valuable aspect is the opportunity to develop the research team and young researchers while conducting joint scientific research and to acquire knowledge and skills, both technical and so-called “soft” skills, during training.

The total project budget amounts to EUR 1,499,925, of which the budget of the Warsaw University of Technology as a project partner is EUR 299,800.

The Twinning instrument of the Horizon Europe programme supports research institutions in developing cooperation with recognised European scientific centres. Projects implemented under this action enable the exchange of knowledge and experience, conducting joint research, developing researchers’ competences and strengthening the organisational potential of institutions. By building lasting international partnerships, Twinning contributes to raising the level of scientific excellence, increasing the competitiveness of universities and research institutions, and their more active participation in European research programmes.