ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING AM for Metal Parts Anna Valente Head of Industrial Robotic Systems for Advanced Manufacturing Technologies Lab SUPSI 2 May 2016

Enlightening Next Generation of Material FoF.2014-2 Manufacturing processes for complex structures and geometries with efficient use of material

Borealis Challenges Variable dimensions of parts

Borealis Challenges Hybrid processes Deposition & Subtraction

Result 1 - Borealis Machine

Result 2 - Borealis Revolver Head

Result 3 - Borealis Control & Monitoring Infrastructure

Prima Industrie IT Supsi-ISTePS CH Polito TNO NE ILT DE LE – AM machine integrator Supsi-ISTePS CH RTD – designer of machine, robots Polito RTD – design of new materials for AM TNO NE RTD – product design ILT DE RTD – laser based AM processes University of Patras GR RTD – energy assessment of the AM and ablation processes IRIS SME – qualification of laser processing performance PE LE – provider of mechatronics and NC platform FRAMOS SME – expert vision systems hardware IRIDA Labs SME – expert vision systems software platforms Synesis SME – providers of automation solutions GLOBOTICS SME – provider of robotic structures OPI Photonics SME – provider of laser source modules Diad Group ES SME – end user in the automotive sector GE - AVIO ITA LE – end user in the aerospace sector Sintea SME – end user in the medtech sector

Exploitable results (ERs) DESCRIPTION OF BOREALIS EXPLOITABLE RESULTS ER1 ER2 ER3 Borealis Machine Borealis Laser Head Borealis Process Monitoring Infrastructure 1A) TYPE OF RESULT Large AM machine for additive and subtractive manufacturing (metal parts) equipped with a multiple nozzles powder ejection system and a smart sensing system for inline loop control Flexible revolver head equipped with two laser sources (CW for metal sintering and pulsed for ablation) and a multiple nozzles system for powder ejection (Near) Real time multi-sensorial monitoring solution integrated with the machine control software architecture

Exploitable results (ERs) DESCRIPTION OF BOREALIS EXPLOITABLE RESULTS ER1 ER2 ER3 Borealis Machine Borealis Laser Head Borealis Process Monitoring Infrastructure 2) POTENTIAL CUSTOMER Industrial sectors with complex parts and low volumes: aerospace and automotive. Users already in AM System integrators 3) BENEFITS TO THE CUSTOMER Realization of large components with AM technologies High level of customization Increased productivity vs current AM technologies Energy footprint certification Complex shape components Functionally graded material (variable composition, variable density…) Integration of several processing steps (AM, heat treatment, surface finishing,…)   Zero faulty parts Process accuracy and repeatability Process parameters optimization Defect Detections Tolerance Monitoring Component Measurement

DESCRIPTION OF BOREALIS EXPLOITABLE RESULTS ER1 ER2 ER3 Borealis Machine Borealis Laser Head Borealis Process Monitoring Infrastructure 4) TRL 4 5 5) MILESTONES FOR TRL9 TRL 4: Lab scale demo (2016) TRL 5: Full size prototype (2017) TRL 6-7: Industrial solution realization (2018-2019) TRL 8: Complete and qualified machine (2020) TRL 9: Competitive manufacturing system (2021) TRL 6-7: Industrial solution realization (2018) TRL 8-9: Competitive laser head (2019) TRL 5: First prototype validation (2016) TRL 8: Final version under expected conditions (2019) TRL 9: Final version under mission conditions (2020) 6) MAIN TECHNICAL CHALLENGES Improved productivity without compromising precision and quality for large components Quick opto-mechanic actuation to adapt parameters (e.g. spot size and focus) to changing processing conditions Multi DoF interpolation over complex profiles To shorten the time available for acquisition/elaboration (enabling factor for next generation closed loop control) 7) TIME-TO-MARKET Q4 - 2021 Q4 -2019 Q4 - 2020 8) IPRS One or more patent applications within the project completion

Expressions of Interest M1-US-QUESTEK   ER1 Al powder ER2 Ti 6-4 Mod alloy ER3 New Co, Ni or other alloy M2-US-EXOVA Design allowable database Standard test & qualification protocols Surface finish for net shape parts ER4 Use of irregular shape powders M3-US-NIU Calorimeter to monitor heat input Acoustic monitoring of powder flow M4-SA-DEDREF DED procedures for repair Image processing

Thank you! anna.valente@supsi.ch