Climate Neutral and Digitalized Laser Based Surface Functionalization of Parts with Complex Geometry

Project Information

CLASCO

Grant agreement ID: 101091373

DOI

10.3030/101091373

Project closed

EC signature date 23 November 2022

Start date 1 January 2023

End date 30 June 2026

Funded under

• Digital, Industry and Space

Total cost

€ 4 829 772,50

EU contribution

€ 4 829 772,50

Coordinated by

TECHNISCHE UNIVERSITAET DRESDEN
Germany

Periodic Reporting for period 2 - CLASCO (Climate Neutral and Digitalized Laser Based Surface Functionalization of Parts with Complex Geometry)

Reporting period: 2024-07-01 to 2025-12-31

Summary of the context and overall objectives of the project

In the coming years, the European industry must assume the challenge of adopting clean and climate-neutral industrial value chains, producing sustainable products. Adopting digital systems will radically change the industry with products and services through innovative production processes. In particular, fully digitalised laser-based additive manufacturing methods are very versatile and thus can be implemented in different industries. Furthermore, energy saves against conventional manufacturing and material waste but also by design optimization can be achieved. However, these parts also required of additional surface treatments, which are nowadays energy and material-consuming, increasing costs and harming the environment. In addition, new concepts for increasing the added value of AM parts must be developed, for instance, by producing advanced surface functionalities in critical applications. The main objective of the CLASCO project is to develop a universal and digitalised laser-based post-process route for creating functionalised AM parts with complex shapes. While the complex parts will be produced by Laser Powder Bed Fusion, Laser polishing and laser surface micro-structuring using Direct Laser Interference Patterning will be combined in a unique manufacturing system. This route will substitute several resource-consuming processes, reducing the environment's negative impact. The implementation will allow substituting standard environmental non-friendly methods and even obtaining a better performance. In addition, different in-line monitoring methods, specifically plasma sensors and infrared cameras will be implemented. In this way, a virtual representation of the process for each part will be possible (digital twin), creating an entirely digitised product. The project's impacts will be analysed to optimise the sustainability of processes and products across the entire life cycle. The project brings together 13 partners from 6 countries, including Spain, France, the UK, Austria, Ireland, and Germany, to combine 3 laser technologies to create advanced parts. CLASCO has six main objectives, including the development of optimized designs, laser-based treatments for advanced surface functionalization, in-line monitoring processes, data acquisition and control feedback loops using machine learning and AI, product demonstrators with high-performance requirements, and validation of resource and energy savings.

The main objectives of the project include:

Objective 1: Development of optimised designs based on additive manufacturing.
Objective 2: Development and implementation of laser-based treatments for advanced surface functionalisation.
Objective 3: Development of in-line monitoring processes.
Objective 4: Development of effective and efficient data acquisition and control feedback loop driven by novel machine learning and artificial intelligence.
Objective 5: Processing of product demonstrators with high-performance requirements.
Objective 6: Validation of lower consumption of resources, energy, and gender dimensions.

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

During the second reporting period, the project progressed from component-level developments towards full system integration and validation. All selected aerospace and biomedical demonstrators were successfully redesigned for additive manufacturing and fabricated using L-PBF technology.
A major milestone was achieved with the completion and commissioning of the CLASCO hybrid laser system. The machine is fully operational and integrates laser polishing and DLIP surface structuring in a single platform capable of processing complex 3D geometries. Surface roughness reduction and deterministic micro- and sub-micrometre structures have been successfully demonstrated on titanium and Scalmalloy components.
The monitoring architecture has been fully implemented. A high-speed MWIR infrared camera and plasma sensors (on-axis and off-axis configurations) are integrated into the system, enabling real-time monitoring of thermal and plasma signals. A structured data acquisition backbone has been established, ensuring synchronised collection of machine, sensor and process data. The system architecture required for closed-loop control and AI-driven optimisation has been deployed and successfully validated at platform level.
Sustainability assessment activities have progressed significantly. Life Cycle Assessment (LCA), techno-economic analysis and social assessment frameworks have been further developed, with preliminary results indicating strong potential for reductions in resource use and environmental impact compared to conventional process routes.
Dissemination, communication and exploitation activities continued actively throughout the period.

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)

During the second reporting period, CLASCO has achieved results that clearly go beyond the current state of the art in laser-based manufacturing and surface functionalisation. The project has successfully realised a fully integrated hybrid laser platform that combines additive manufacturing post-processing, laser polishing, Direct Laser Interference Patterning (DLIP), and multi-sensor in-line monitoring within a single digitalised system.
The CLASCO machine represents a unique system worldwide, as no existing platform integrates laser polishing, DLIP structuring, real-time infrared and plasma monitoring, and a structured data architecture prepared for closed-loop control in one unified manufacturing environment capable of processing complex three-dimensional parts. This level of functional and digital integration significantly advances beyond currently available standalone or partially integrated solutions.
Technologically, the project has demonstrated substantial surface roughness reduction and the fabrication of deterministic micro- and sub-micrometre surface structures on complex titanium and aluminium alloy geometries. The successful integration of high-speed MWIR thermography and plasma monitoring enables real-time process observation and provides the foundation for adaptive, closed-loop process control.
Furthermore, the established digital backbone and AI-supported modelling approaches enable synchronised acquisition and analysis of machine and sensor data, forming the basis for self-learning manufacturing systems. In combination with the demonstrated potential for reduced material waste, auxiliary materials and energy consumption, CLASCO establishes a new benchmark for sustainable and intelligent laser-based surface functionalisation of additively manufactured components.

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