1. 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

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

3. Borealis Challenges
Variable dimensions of parts

4. Borealis Challenges
Hybrid processes
Deposition &
Subtraction

5. Result 1 - Borealis Machine

6. Result 2 - Borealis Revolver Head

7. Result 3 - Borealis Control & Monitoring Infrastructure

8. 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

9. 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

10. 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

11. 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 ( )
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 Q Q Q 8)
IPRS
One or more patent applications within the project completion

12. 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

13. Thank you! anna.valente@supsi.ch