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Combining DISsimilar materials into functional large-scale and light-weight COmponents and structures

Project description

A novel way to manufacture multi-material functional components

Hybrid manufacturing methods combine two or more manufacturing techniques, such as additive and subtractive manufacturing, and can be used to produce complex parts with unique properties and features. The EU-funded DISCO2030 project is a research initiative aimed at developing and demonstrating two first-of-a-kind hybrid manufacturing methods that can join dissimilar metal-metal and metal-polymer materials by combining powder bed fusion and directed energy deposition. The project's ultimate goal is to create lightweight, complex-geometry multifunctional devices with graded materials that can operate in harsh environments such as rocket engines, marine engines and cryogenic hydrogen fuel tanks. DISCO2030 will pave the way for new standards for dissimilar material joining and testing, and boost EU leadership in additive manufacturing by developing cost-effective, efficient and flexible manufacturing techniques.


The DISCO2030 project aims to develop two innovative hybrid manufacturing methods for joining dissimilar metal-metal and metal-polymer materials. Both proposed methods are underpinned by additive manufacturing (AM) technologies from the emerging technology families of Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). DISCO2030 combines the advantages of PBF and DED to enable the manufacturing of multi-material lightweight, complex geometry components/structures that are able to operate in harsh environments. The process is expected to achieve a ≥20% lead time reduction compared to state-of-the-art manufacturing processes (such as die casting and brazing) and manufacture multi-material parts that have a 50% lower weight compared to reference products and a 30% higher performance (achieved among others by graded materials).

The three use-cases to be demonstrated in the project are of high relevance to the EU economy and include a rocket engine, a marine engine and a cryogenic hydrogen tank for primary applications in the automotive sector. All components manufactured using the novel DISCO hybrid manufacturing methods will be subjected to rigid testing according to the respective industry standards.

DISCO2030 is expected to generate significant impact by paving the way for the creation of new dissimilar material joining and testing standards, strengthening the EU’s leadership in AM technologies and increasing the EU’s resilience against global supply chain disruptions. Finally, DISCO2030 will contribute to the reinvention of the European aerospace, marine and automotive sectors, ultimately providing EU citizens with better, more sustainable and cost-effective transportation.


Net EU contribution
€ 1 298 122,50
Arcisstrasse 21
80333 Muenchen

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Bayern Oberbayern München, Kreisfreie Stadt
Activity type
Higher or Secondary Education Establishments
Total cost
€ 1 298 122,50

Participants (8)

Partners (1)