Flexible Laser-based manufacturing through precision photon distribution

Project Information

FLASH

Grant agreement ID: 101138380

DOI

10.3030/101138380

EC signature date 10 December 2023

Start date 1 January 2024

End date 31 December 2026

Funded under

• Digital, Industry and Space

Total cost

No data

EU contribution

€ 4 131 800,25

Coordinated by

ALTFORM S.R.L.
Italy

Periodic Reporting for period 1 - FLASH (Flexible Laser-based manufacturing through precision photon distribution)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

The FLASH project—Flexible Laser-based manufacturing through precision photon distribution, was conceived in response to an urgent industrial and political imperative: modernize European manufacturing by advancing the digital and green transitions. Across sectors like medical devices, automotive, tooling, and e-mobility, manufacturers are facing challenges including high energy consumption, production inflexibility, increased defect rates, and long setup times. The current landscape is strained by global competition, regulatory pressures, and sustainability demands. FLASH aims to tackle these problems head-on by developing a versatile, high-performance laser platform that integrates three distinct laser sources, real-time optical and acoustic monitoring, dynamic beam shaping, and hybrid robotic/CNC processing capabilities, all orchestrated by AI-driven control systems and cloud-based digital infrastructure.

Motivated by the EU’s strategic goals in the Green Deal and the Made in Europe Partnership, FLASH brings together technology providers, industry leaders, and social science researchers to build a tool capable of reducing production time, energy consumption, and defect rates across complex manufacturing scenarios. The project is designed around five industrial use cases in four different industry sectors, from acetabular implants and dissimilar metal joints to copper hairpin welding and superabrasive grinding tools, providing immediate pathways for validation and scale-up. Each of these cases demonstrates FLASH’s capacity to replace multi-step processes with streamlined, modular, and sustainable workflows.

The project’s pathway to impact includes extensive work on life cycle analysis (LCA), cost-benefit modeling, and predictive simulation, ensuring that environmental and economic metrics are considered from design to deployment. Clustering with sister EU projects, engagement in standardization efforts, and the development of training modules reinforce the societal and policy alignment of FLASH. Critically, the integration of social sciences and humanities plays a pivotal role, foresight analysis and stakeholder engagement inform technology adoption strategies, while educational workshops foster skills development and inclusiveness.

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

FLASH project focused intensely on developing and validating critical components for a modular, AI-optimized, multi-laser manufacturing platform. Major efforts included integrating three laser sources (CW/QCW infrared, short-pulse green, and long-pulse green) into a unified optical path, engineered with custom fiber-coupling and switching modules. Beam delivery heads, nozzle-based, scanner-based, and water-jet-guided, were prototyped and characterized for focus precision, power transmission, and dynamic shaping capabilities using deformable Zwobbel mirrors. A hybrid process monitoring system was created to capture real-time acoustic and optical signals with synchronized data acquisition software. AI models were developed for predictive tuning of process parameters and sustainability metrics, while digital twin dashboards were set up for KPI tracking. The PRIMA IANUS demonstrator was retrofitted with a robotic arm, rotary/tilt CNC stages, and automated laser head switching, achieving high positional accuracy and operational readiness. Simulations and experimental laser routines were conducted for five use cases ranging from titanium implants and metal joining to grinding wheel manufacture and copper hairpin welding. Lifecycle assessment tools and environmental data collection protocols were embedded into process selection workflows to ensure sustainability-driven design.

Main Scientific Achievements:
- Full commissioning of three synchronized laser sources with fiber-coupled delivery and switching modules.
- Dynamic beam shaping prototypes validated with rapid profile modulation and focus shifting (≤2 ms).
- Zwobbel mirror tests confirmed stable, responsive curvature control and beam steering.
- Real-time hybrid process monitoring system built and ready for machine integration.
- PRIMA IANUS demonstrator retrofitted with robotic/CNC systems, extra storage laser head cabinet and automated tool-switching stations.
- Precision laser routines developed for five use cases with improved part quality and process speed.
- Multiphysics simulations completed for copper welding and laser drilling, aiding parameter refinement.

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 FLASH project has delivered critical innovations toward next-generation laser-based manufacturing, including the integration of three distinct laser sources, dynamic beam shaping modules, acoustic–optical process monitoring, and machine learning–driven control systems, all embedded in a hybrid robotic/CNC demonstrator. These results underpin five high-impact industrial use cases, each demonstrating improved energy efficiency (up to 65%), productivity (50% faster processing), and reduced defect rates. Early lifecycle analyses suggest up to 80% environmental impact reduction over conventional methods.

To support the continued uptake and success of the FLASH platform, a number of enabling actions are essential. First, further research and demonstration activities are needed to validate the machining processes through high-complexity industrial trials, expand machine learning models on broader datasets, and extend the scope of hybrid and multi-wavelength laser technologies. Access to markets and finance must also be prioritized, particularly by enabling investment mechanisms and adoption incentives for SMEs and industry integrators. On the commercialisation front, developing scalable business models and finalising IP licensing agreements will help transition the technology from prototype to market-ready solutions tailored to key industry verticals. Internationalisation efforts should include deeper collaboration with standardisation bodies, as well as EU-wide clustering activities to boost visibility and global reach. Crucially, aligning with supportive regulatory frameworks will help ensure compliance, accelerate adoption, and establish FLASH as a leader in sustainable advanced manufacturing.