Integration of Advanced Experiments, Imaging and Computation for Synergistic Structure-Performance Design of Powders and Materials in Additive Manufacturing

Project Information

SynAM

Grant agreement ID: 101129996

DOI

10.3030/101129996

EC signature date 16 October 2023

Start date 1 January 2024

End date 31 December 2027

Funded under

• Marie Skłodowska-Curie Actions (MSCA)

Total cost

No data

EU contribution

€ 565 800,00

Coordinated by

POLITECHNIKA SLASKA
Poland

Periodic Reporting for period 1 - SynAM (Integration of Advanced Experiments, Imaging and Computation for Synergistic Structure-Performance Design of Powders and Materials in Additive Manufacturing)

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

Summary of the context and overall objectives of the project

Additive manufacturing (AM), often referred to as 3D printing, is transforming traditional manufacturing by enabling unprecedented design flexibility, rapid prototyping, and customization. However, significant challenges remain, such as controlling material properties, predicting structural integrity, and managing surface quality—particularly regarding corrosion resistance and functional reliability. These challenges limit AM’s broader industrial application, especially with advanced materials requiring precise phase control, like duplex stainless steels, amorphous glass metals, and magnesium alloys.

The overarching objective of this project is to integrate state-of-the-art data systems, experimental approaches, imaging techniques, machine learning, and predictive physical modeling to address these critical challenges in AM. By establishing a comprehensive data repository encompassing structural characteristics, defects, distortions, and performance metrics across various material scales, the project aims to significantly enhance materials development and optimize AM processes.

Through interdisciplinary collaboration between academia and industry, this initiative seeks to systematically quantify how AM processing parameters and surface treatments affect material integrity and functional properties. The project further intends to develop advanced imaging methods and processing algorithms, ensuring consistent quality control, from initial powder production through final manufacturing.

A unique aspect of this project is the fusion of physical modeling with machine learning, enabling predictive design of optimal material compositions and structures. The anticipated outcomes include enhanced printability, improved mechanical and corrosion-resistant properties, and streamlined development cycles. These advancements will substantially impact industrial capabilities, aligning with strategic EU priorities related to Industry 4.0 and Industry 5.0.

Ultimately, by fostering international and cross-sectoral knowledge transfer, this project aims to accelerate the application of innovative AM solutions, enhancing competitiveness, sustainability, and technological leadership within the EU and globally.

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 initial phase of the project, substantial technical and scientific progress was achieved, specifically focusing on duplex stainless steels and magnesium alloys. The consortium successfully established advanced data management systems tailored explicitly for additive manufacturing (AM), systematically collecting and analyzing critical structural, property-related, and performance data across different scales for these materials.

Detailed experimental investigations were conducted to characterize defects, distortions, and overall material integrity, particularly emphasizing duplex stainless steels and magnesium alloys. This in-depth characterization provided essential data, facilitating the creation of a comprehensive data repository dedicated to these materials.

Significant developments were also made in image processing techniques, resulting in an effective predictive framework aimed at optimizing material compositions and structures. Advanced imaging methodologies enabled precise analysis and assessment, leading to improved accuracy in predicting material performance and structural characteristics for duplex stainless steels and magnesium alloys.

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 project significantly advanced additive manufacturing (AM) technologies through integrated data management, advanced characterisation techniques, and innovative predictive frameworks. These advancements enhanced the optimization of material properties and structural integrity, providing a foundation for broader industrial applications. The potential impacts of these advancements include enhanced material performance, greater reliability, and expanded utilisation across various sectors. To ensure sustained progress and adoption, key actions must be taken, including further research and demonstration activities, enhanced market access strategies, intellectual property management, international collaboration, and the establishment of supportive regulatory and standardisation frameworks. These measures are expected to facilitate the commercialisation and integration of advanced AM technologies.