Human‑Centred AI for Circular Photovoltaic Manufacturing
Progress Update from the CIRCMAN5.0 Consortium
As CIRCMAN5.0 completed its first year, the consortium continues to advance the development of a human‑centred, AI‑enabled digital framework that supports circularity across the photovoltaic (PV) value chain. This second newsletter highlights key achievements from 2025 to early 2026, including technical developments, stakeholder engagement, pilot preparation, and participation in major European events.
Strengthening the Foundations of Circular PV Manufacturing
Mapping Challenges and Opportunities Across the PV Lifecycle
Throughout 2025, the consortium analysed the scientific and industrial challenges that limit circularity in PV manufacturing. These include material selection, resource planning, supply‑chain collaboration, manufacturing process adaptation, performance diagnostics, recovery strategies, and logistics optimisation. These insights directly inform the design of CIRCMAN5.0’s technological solutions and ensure alignment with real industrial needs.
Defining the CIRCMAN5.0 Architecture
Technical partners finalised the first version of the integrated architecture, bringing together:
- AI‑driven eco‑design and modelling tools
- A Cognitive Digital Twin for manufacturing
- ML‑assisted production planning
- A comprehensive LCA and circularity assessment framework
- A Distributed Ledger–enabled Digital Product/Material Passport (DPP)
- A Human‑in‑the‑Loop Decision Support System
This architecture forms the backbone of the CIRCMAN5.0 ecosystem and guides the development of the project’s 15 innovative technology solutions.
Technical Developments Across Work Packages
Advancing Digital Twins, AI Models, and LCA Tools
During the second half of 2025 and early 2026, Work Packages 2–4 made significant progress:
- Ontological Production Information Modelling (IS1) is being refined to support semantic interoperability.
- AAS‑based Digital Twin prototypes (IS2) are under development for real‑time simulation and monitoring.
- AI‑driven parametric eco‑design tools (IS3) are being prepared to support circular‑by‑design PV products.
- ML‑assisted production planning (IS4) is progressing toward early integration with pilot data.
- Environmental impact forecasting, routing optimisation, and LCA modules (IS6–IS11) are being designed to quantify embodied energy, carbon footprint, and circularity metrics.
These developments will enable manufacturers to reduce waste, optimise resource use, and improve environmental performance across the PV lifecycle.
Digital Product/Material Passport (DPP) and Data Governance
A major focus of late 2025 and early 2026 has been the development of the Digital Product/Material Passport, which will support transparent, secure, and verifiable tracking of materials across the PV value chain. Current work includes:
- Designing the DPP architecture using Distributed Ledger Technologies
- Defining data models aligned with FAIR principles and EU DPP initiatives
- Preparing integration with the CIRCMAN5.0 Collaborative Space
This will enable new circular business models and improve traceability, trust, and data accessibility across the sector.
Pilot Site Preparations
From autumn 2025 onwards, the four industrial pilot partners—ONYX (Spain), SUNAGE (Switzerland), ASCA (Germany), and SOLITEK (Lithuania)—began preparing for the integration of CIRCMAN5.0 tools. Each pilot will validate different aspects of the framework, including:
- Circular product design
- Production planning and process optimisation
- Environmental impact assessment
- End‑of‑life recovery and material revalorisation
Dedicated technical meetings were organised to facilitate this integration and resolve any early challenges.
CIRCMAN5.0 in the European Research & Innovation Landscape
CIRCMAN5.0 Workshop Series on Data Spaces – May & June 2025
A two‑part workshop series explored the role of Data Spaces in circular PV development:
- Session 1 (May 2025): Introduction to Data Spaces, benefits, and controlled data sharing.
- Session 2 (June 2025): Deep dive into the IDSA Reference Architecture Model and technical components such as Connectors, Identity Providers, Metadata Brokers, and Clearing Houses.
The workshops outlined a phased adoption path for pilot partners, beginning with mock data exchanges and gradually expanding to external stakeholders.
EU Circularity Cluster: Digital Product Passport Exchange – July 2025
July 2025 marked a strong focus on Digital Product Passports (DPPs) across the EU Circularity Cluster. The seven HaDEA‑funded projects under the HORIZON‑CL4‑2024‑TWIN‑TRANSITION‑01‑05 call—working collectively within the Made in Europe Partnership with EFFRA—brought together their technical experts for a dedicated knowledge‑exchange session.
The meeting centred on sharing approaches, challenges, and early learnings around DPP development. This collaborative effort is helping accelerate progress across the cluster, strengthening efficiency, creativity, and innovation in the transition toward circular, data‑driven manufacturing.
CIRCMAN5.0 Clustering and Cohesion Advisory Board (CCAB) Meeting- September 26, 2025
On 19 September 2025, CIRCMAN5.0 held its first Clustering and Cohesion Advisory Board (CCAB) meeting, bringing together external experts and project partners to review progress, exchange insights, and strengthen collaboration across the consortium.
The session opened with an overview of the project by Project Coordinator Angeliki Zacharaki (CERTH), followed by a presentation of the technical architecture and components by Technical Coordinator Sotiris Messinis (ICCS–NTUA). These introductions set the stage for a productive discussion on the project’s direction, challenges, and opportunities.
The Advisory Board’s guidance plays a crucial role in ensuring that CIRCMAN5.0 delivers meaningful impact, drives innovation, and maintains strong cohesion across all work packages. Their feedback will help refine the project’s technical roadmap and reinforce alignment with industry needs and European priorities.
A warm thank‑you to our Advisory Board members — Maria Jose Nuñez Ariño, Holger Berg, John Soldatos, and Cosmin Septimiu — for their active engagement and valuable contributions. Their expertise strengthens the project’s foundations as we move into the next phase of development.
ESS Expo 2025 in Birmingham – September 2025
The project contributed to the Circular Economy Theatre sessions, sharing insights and learning from other initiatives shaping the future of circular industrial practices.
First Research Paper Presented – November 2025
CIRCMAN5.0 presented its first research paper, “Empowering Circular Value Chains in the PV Manufacturing Industry: A Human‑in‑the‑Loop Vision from the CIRCMAN5.0 Framework”, at the 7th International Conference on Industry of the Future and Smart Manufacturing (University of Malta).
The full paper is available on our website.
EFFRA Event on Manufacturing Innovation – November 2025
CIRCMAN5.0 was represented at the EFFRA Manufacturing Innovation event, where the project coordinator presented ongoing work and highlighted contributions to circular manufacturing and digitalisation. Sister projects ENCIRCLE and Digi4Circular also participated, reinforcing the EU Circularity Cluster collaboration.
GDDS Connect 2025 – December 2025
CIRCMAN5.0 was featured at GDDS Connect 2025, where CERTH presented the project’s role in enabling circularity in the PV sector through data‑driven collaboration and Data Spaces.
3rd Plenary Meeting in Lugano – December 2025
The consortium gathered at SUPSI in Lugano for its third plenary meeting, reviewing progress and planning next steps across all work packages. The meeting strengthened collaboration and aligned partners on upcoming technical milestones.
Looking Ahead 2026
In the coming months, CIRCMAN5.0 will:
- Release the first prototypes of the Digital Twin, eco‑design tools, and LCA modules
- Launch the initial version of the Digital Product/Material Passport
- Release the first version of CIRCMAN5.0 Platform
- Begin integration activities with the four pilot sites
- Continue co‑creation workshops and stakeholder engagement
- Publish new communication materials and technical updates
The consortium remains committed to driving innovation in circular PV manufacturing and supporting Europe’s transition to a sustainable, resource‑efficient energy future.
Stay Connected & Join the Community
Follow our updates and engage with us:
- Website: https://circman5.eu/
- X: @circman5
- LinkedIn: @CIRCMAN5.0
Project partners are invited to share their social media handles so we can highlight and promote your contributions.
Thank You
Thank you for your continued interest and support. CIRCMAN5.0 is a collaborative journey, and we look forward to advancing the frontiers of circular and human‑centric manufacturing together.
The CIRCMAN5.0 Consortium Team