Green Additive Manufacturing through Innovative Beam Shaping and Process Monitoring

Project Information

InShaPe

Grant agreement ID: 101058523

DOI

10.3030/101058523

Project closed

EC signature date 18 May 2022

Start date 1 June 2022

End date 31 May 2025

Funded under

• Digital, Industry and Space

Total cost

€ 7 216 933,00

EU contribution

€ 7 216 931,25

Coordinated by

TECHNISCHE UNIVERSITAET MUENCHEN
Germany

Periodic Reporting for period 2 - InShaPe (Green Additive Manufacturing through Innovative Beam Shaping and Process Monitoring)

Reporting period: 2023-12-01 to 2025-05-31

Summary of the context and overall objectives of the project

The InShaPe project was launched to tackle pressing technological, economic, and environmental challenges in the field of metal additive manufacturing (AM), particularly Laser-based Powder Bed Fusion of metals (PBF-LB/M). Although AM offers unmatched design flexibility and decentralized production potential, conventional laser beam profiles—mainly Gaussian—limit productivity, microstructural control, and material efficiency. As Europe advances its twin transition towards green and digital industrial production, there is a clear need for more adaptive, resource-efficient, and intelligent AM processes.
In response, InShaPe brings together 11 partners from academia and industry across Europe to develop and validate a next-generation PBF-LB/M process based on two key innovations:
1. An AI-based beam shaping module, enabling application-specific, energy-efficient beam profiles, and
2. An in-situ multi-spectral monitoring system that supports process control and predictive quality assurance.
The project aims to dramatically enhance performance and sustainability, targeting a 7-fold increase in productivity, 50 % cost reduction, 60 % lower energy use, and 30 % less scrap. These ambitious goals are being tested and demonstrated across four industrial domains: aerospace, energy, space, and forestry.
Ultimately, InShaPe supports the European Union’s strategic objectives by enabling greener, smarter, and more competitive manufacturing, strengthening digital sovereignty, and reinforcing Europe’s leadership in advanced industrial technologies.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The InShaPe project followed a structured methodology comprising four key research and development phases: specification, development, integration & validation, and demonstration. Each phase was aligned with the overall objective of enabling intelligent, high-performance, and resource-efficient metal additive manufacturing through laser beam shaping and in-situ monitoring technologies.
1. Specification
The project began with the technical baselining of four industrial use cases, covering sectors such as aerospace (Oerlikon), energy (BeamIT), space (AENIUM), and forestry (AMEXCI). Each use case brought specific material and process challenges, including complex geometries, high-strength requirements, microstructure control, and cost-efficiency goals. A fifth use case—an antenna cluster by Airbus—was later defined through the Open Innovation Service. Based on these applications, key technical requirements were formulated for beam shaping configurations and monitoring hardware/software.
2. Development
In the beam shaping domain, a framework for generating and evaluating custom laser profiles was created. Various beam shapes were defined and physically implemented using three platforms:
• A flexible LCOS-SLM system for research and microstructural tailoring,
• A DOE-based optical module for stable, cost-effective industrial use,
• A multi-core fiber system (AFX) offering robustness and scalability.
In parallel, a multi-spectral imaging (MSI) monitoring system was developed, including a SWIR-adapted and a VIS/NIR-adapted camera.
3. Integration and Validation
The beam shaping modules and MSI hardware/software were successfully integrated into an EOS M290 system, creating a demonstrator platform with fully digital control.
4. Demonstration
In the final phase, all use cases were printed using the full InShaPe technology stack. The target build rates were met or exceeded in all cases, with some partners achieving up to 6× the baseline productivity. While surface roughness targets were not fully reached, particularly in downskin regions, the demonstrators confirmed the potential of InShaPe technologies to meet industrial expectations. Additionally, cost reductions of up to 57 % and significant energy and scrap savings were validated through real builds, especially in Oerlikon’s impeller case.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The InShaPe project delivered significant breakthroughs advancing Laser Powder Bed Fusion of Metals:
Innovative Laser Beam Shaping:
Custom beam shapes enable microstructure control, surpassing conventional Gaussian beams in tailoring grain size, texture, and morphology.

Major Productivity Gains:
Adaptive beam profiles combined with optimized scanning increased build rates up to 6 times, greatly improving throughput and cost-efficiency.

Monitoring with MSI:
A novel multi-spectral imaging system provides accurate, spatially resolved melt pool temperature and emissivity data.

Cross-Industry Validation:
Proven in aerospace, energy, space, and forestry sectors, demonstrating versatility and industrial readiness.

Sustainability Improvements:
Achieved up to 73 % energy savings and 58 % scrap reduction, supporting greener manufacturing aligned with EU goals.

Talent Development and Market Engagement:
Educated eight PhD candidates and showcased technology via trade shows, publications, and an Open Innovation Service to accelerate industrial adoption.

InShaPe innovations - beam shaping and multi-spectral imaging

InShaPe - Key Result