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.
