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Made-to-measure micromachining with laser beams tailored in amplitude and phase

Description du projet

La technologie laser pour rendre les lignes de production industrielle plus propres et plus vertes

Les procédés de fabrication écologiques protègent la planète de l’exploitation et préservent les ressources naturelles. L’industrie mondiale devient ainsi plus durable et plus respectueuse de l’environnement. Le projet METAMORPHA, financé par l’UE, créera un dispositif numérique unique, entièrement électrique, basé sur le micro-usinage par laser à impulsions ultracourtes. Il remplacera les processus mécaniques et chimiques de nombreuses lignes de production conventionnelles, tout en ne produisant aucun déchet chimique. En outre, étant à la fois agile et évolutive, il promet d’éliminer la nécessité de milliers de processus de production qui ont un impact négatif sur l’environnement. Une analyse du cycle de vie (ACV) et une ACV sociale seront réalisées pour évaluer ses avantages environnementaux et socio-économiques.

Objectif

"The METAMORPHA concept is a single agile USP laser micromachining platform to replace many conventional manufacturing process chains. It has the potential to eliminate thousands of environmentally damaging production processes. METAMORPHA is all-electric, all-digital, produces no waste chemicals and enables novel processes for product rework and repair.
All-in-one module: The key to this agility is a combination of two cascaded spatial light modulators (SLM) and a galvo scanner resulting in the most sophisticated beam shaping and steering ever developed. This allows a single module to perform the job of several laser processing heads: e.g. polishing, milling, drilling and cutting (importantly including any wall angle).
Made-to-measure laser processes: Each infeed component is scanned with a high resolution 3D sensor. A machine learning algorithm determines an individualised laser process to maximise efficiency and ensure ""first time right"".
In-line process control: Data from additional online sensors are processed using an edge device running a self-learning algorithm to provide real-time feedback for system control. The ultra-fast edge-based signal processing and synchronisation are key project topics.
Agile and scalable: Suitable for any standard industrial production line including 2-, 3- or 5-axis, rotating and roll-to-roll, and for scale up to parallel processing with multiple modules. The three end use cases (UCs) show the versatility and scope for replacing existing process chains:
UC-1 PHILIPS: Small complex metal parts (shaving heads) requiring 90 degree wall angles.
UC-2 TKSE: Large area embossing rollers and the re-writing of old rollers.
UC-3 CERAT: Very hard carbide parts and refurbishment of worn parts.
Sustainability assessment: A life cycle analysis (LCA) and social LCA will be carried out to quantify the environmental and socioeconomic benefits. A detailed plan for exploitation and an extensive dissemination and communication plan are in place."

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Coordinateur

FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
Contribution nette de l'UE
€ 1 486 827,00
Adresse
Hansastrasse 27c
80686 Munchen
Allemagne

Voir sur la carte

Région
Bayern Oberbayern München, Kreisfreie Stadt
Type d’activité
Research Organisations
Liens
Autres sources de financement
€ 0,50

Participants (11)