Nordborg, Denmark – From 19th to 20th May 2026, the Smart-Pumps consortium gathered at the Danfoss headquarters for our second Annual General Assembly. Marking the two-year milestone of the project, this event was a key step in planning the transition from theoretical research and laboratory development to the physical manufacturing and testing of our next-generation heat pump components. 

Hosted by our industrial partner Danfoss, the meeting brought together onsite representatives from the Hellenic Mediterranean University (HMU), the Centre for Research & Technology Hellas (CERTH), AIMEN, and Deep Blue, alongside partners connected remotely. 

The Decarbonisation Tour 

The assembly began with a practical start: a Decarbonisation Tour led by the Danfoss team. Walking through fully operational examples of industrial decarbonisation provided useful context for the technical discussions that followed, aligning perfectly with the real-world impact our project aims to achieve. 

Tackling Manufacturing Challenges 

Project Coordinator Associate Professor Agathoklis Krimpenis (HMU) opened the General Assembly highlighting how Smart-Pumps is currently entering its critical implementation phase. Reflecting this shift, the core of the discussions centred on detailed technical sessions regarding the physical design of the heat pump’s components. 

Pushing the boundaries of robotic DED 3D metal printing and Hybrid Manufacturing involves significant engineering challenges. A major focal point was the manufacturing of the Gyroid main Heat Exchanger (as evaporator and condenser) and “Hive” Internal Heat Exchanger. Achieving thin walls and complex geometries via Additive Manufacturing requires high precision. The consortium actively discussed new path-planning strategies (such as Z-direction slicing and staggered patterns) and evaluated hybrid manufacturing approaches to ensure these critical components meet the required performance standards. This shared problem-solving approach reinforces the consortium’s capacity to successfully deliver these complex components. 

Smart Sensing and System Integration 

Another key topic discussed during the assembly was the practical implementation of our sensor strategy. The team, spearheaded by CERTH, provided detailed updates on the non-intrusive ultrasonic sensors for refrigerant monitoring. Focusing on the established strategy of mounting them externally on the piping system rather than embedding them, the consortium reviewed how this will successfully minimise hardware modifications while feeding real-time data into the heat pump’s control loop.  

Furthermore, looking ahead to the EN 14825 testing phase scheduled for late 2026, Danfoss and AIMEN aligned on strict cleaning and verification protocols for the additively manufactured parts, ensuring a smooth handover and the ability to proceed flawlessly with the testing operations at Danfoss’s Advanced Development Center (ADC) test facilities.  

Inside the Application Development Center (ADC) 

To bring these testing preparations to life, the second day featured a dedicated tour of the Danfoss ADC. The consortium had the opportunity to walk through the exact testing environments where the Smart-Pumps technologies will be validated. Seeing the actual heat pump that will be used for the upcoming validation phase provided a tangible reality to the project’s operations, bridging the gap between digital engineering and real-world application.

Inside the Danfoss Application Development Center (ADC): a glimpse into the testing environment and the actual heat pump scheduled for the Smart-Pumps validation phase. 

Year 2 Highlights and the Road Ahead 

Wrapping up the activities of the second year showcased the journey from our last meeting in Porrino (Spain) to today. As we enter the third and final year of the project, our path is well-defined: 

  • Manufacturing: finalising the physical prototypes of the optimised components (main, heat exchanger, internal heat exchanger, and consolidated distributor/collector). 
  • Testing: coordinating a comprehensive testing campaign, with components moving between the facilities of AIMEN, HMU, and Danfoss for multiple rounds of validation.  
  • Training: outlining potential educational approaches, including the development of Virtual Reality (VR) modules by Deep Blue for installers and the framework for future theoretical workshops.  

The countdown to the final year has officially begun. With a busy schedule of prototype testing, Virtual Reality validation, and technical workshops ahead, the consortium is fully focused on the intermediate milestones leading up to the final project event in Rome in 2027.