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Novel ALL-IN-ONE machines, robots and systems for affordable, worldwide and lifetime Distributed 3D hybrid manufacturing and repair operations

Objective

From aeronautics to oil&gas, complex metal parts embrace major challenges across their lifecycles from the green field intensive manufacturing to the numerous maintenance and repairing operations worldwide distributed. The synergic combination of additive and subtractive processes could overcome individual shortcomings, going beyond the simple succession of steps. 'Plug and produce' modular approach is a key factor to success for such hybridization.

In this scenario, 4D will deliver 4 disruptive breakthroughs:
• A set of four elementary modules specifically designed for AM that embed the control and monitoring systems which can be integrated on new or existing concepts of machines and robots to realize different processes ranging from the DED (powder and wire) to ablation and cold spray;
• A new concept of CNC, constituting a high level sw layer which can be integrated on the top of commercial CNCs, and it is conceived as open to embed portions of the 4D modules control;
• A validated process model to fully exploit the synergistic interactions among elementary processes;
• A dedicated 4D Engineering CAD/CAE/CAM Platform, which covers the lifecycle of the reference product family where multiple processes and hybrid resources are integrated for the (re)manufacturing stage.
Innovation will be physically demonstrated at three possible levels of hybridization:
• Modules - Small hybrid modules, integrated on new special machines, focusing on portable units for certified in-situ repair operations;
• Hybrid Machines – Hybridization on existing robots and machines;
• Production lines - Hybridization of a flexible production line focusing on new concepts for AM mass production.
Potential impact:
>30% lifecycle cost reduction, unprecedented possibility to customise process applications by combining several processes on several different machines, concrete business perspective supported by detailed business plan with deep market and cost analysis: payback 3y ROI>20%

Fields of science (EuroSciVoc)

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Keywords

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Programme(s)

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Topic(s)

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Funding Scheme

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RIA - Research and Innovation action

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Call for proposal

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(opens in new window) H2020-IND-CE-2016-17

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Coordinator

PRIMA ELECTRO SPA
Net EU contribution

Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.

€ 443 750,00
Address
STRADA CARIGNANO 48 2
10024 Moncalieri
Italy

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Region
Nord-Ovest Piemonte Torino
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Links
Total cost

The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.

€ 443 750,00

Participants (19)

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