Multi-scale multi-process machine for high value-added products with disruptive functionalities

Project Information

WISE

Grant agreement ID: 101138718

DOI

10.3030/101138718

EC signature date 7 December 2023

Start date 1 January 2024

End date 31 December 2026

Funded under

• Digital, Industry and Space

Total cost

No data

EU contribution

€ 5 573 813,75

Coordinated by

ALTFORM S.R.L.
Italy

Periodic Reporting for period 1 - WISE (Multi-scale multi-process machine for high value-added products with disruptive functionalities)

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

Summary of the context and overall objectives of the project

WISE project emerges in response to the urgent need for Europe’s manufacturing industries to deliver smarter, more sustainable, and higher‑value products in strategic sectors such as MedTech, Aerospace, and Power Generation, where performance, reliability, and customisation are critical to competitiveness. Traditional manufacturing methods, even advanced additive manufacturing, remain constrained by a geometry‑driven approach, limited integration of micro‑ and nano‑scale features into macro‑scale components, fragmented production chains, and long lead times that inflate costs and slow innovation. At the same time, European political and strategic priorities, from the Green Deal to industrial resilience strategies, demand energy‑efficient, resource‑conscious, and technologically sovereign manufacturing capabilities. Against this backdrop, WISE aims to redefine the frontier of product complexity by shifting the design paradigm from shape‑driven to function‑driven manufacturing.

The project will deliver a TRL7 integrated multi‑process machine that unites macro‑scale Directed Energy Deposition (DED) with hybrid blue–IR lasers and micro/nano‑scale processes such as femtosecond and nanosecond laser ablation, Two‑Photon Polymerisation (2PP), and Direct Atomic Layer Processing (DALP). This single platform will enable the layer‑wise integration of smart functionalities — including self‑healing, triggered biomolecule diffusion, and autonomous repair — directly into complex components.

Three industrial demonstrators will showcase its transformative potential: a spinal cage prosthesis with enhanced healing and reduced rejection risk for MedTech; a turbine blade with self‑healing coatings and improved corrosion resistance for Aerospace; and a self‑repairing patch for hydroelectric pipelines in Power Generation.

By enabling flexible, AI‑driven product engineering, WISE will reduce design‑to‑manufacturing lead times by up to 30% and accelerate design adaptation by 50%, while achieving unprecedented precision and scalability, with deposition rates up to 500 cm³/h and resolution down to 500 nm.

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 reporting period, the WISE consortium advanced from conceptual design to functional subsystems and early demonstrator trials. Mechanical design defined the structural layout, optical beam delivery, and modular heads for rapid switching between additive, subtractive, and functionalisation processes, supported by a precise control architecture. DED parameters were optimised to approach 500 cm³/h while ensuring metallurgical integrity, with hybrid blue–IR lasers improving absorption in reflective metals. Femtosecond/nanosecond ablation, 2PP, and DALP were refined for sub‑micron features and tailored coatings. An AI‑driven monitoring and control system, integrating optical, thermal, and profilometry sensors, enabled adaptive adjustments to improve consistency, reduce defects, and shorten tuning cycles. Materials research confirmed compatibility of alloys, polymers, and coatings, enabling direct integration of self‑healing, bioactive, and corrosion‑resistant functions. Proof‑of‑concept trials validated these capabilities in initial builds of three industrial demonstrators: a spinal cage prosthesis with antibacterial and bioactive surfaces (MedTech), a turbine blade with self‑healing thermal barrier coatings (Aerospace), and a self‑repairing patch for hydroelectric pipelines (Power Generation).

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)

WISE has delivered substantial technical and scientific results that position it as a disruptive enabler for next‑generation manufacturing. The TRL7 multi‑process machine architecture has been fully designed and its core modules, hybrid blue–IR DED head, femtosecond/nanosecond laser ablation units, Two‑Photon Polymerisation (2PP) system, and Direct Atomic Layer Processing (DALP) station, have been realized and validated at subsystem level. Process optimisation has achieved deposition rates up to 500 cm³/h with sub‑micron resolution, while Round Robin testing across the three industrial use cases (MedTech spinal cage, Aerospace turbine blade, and Power Generation healing patch) has demonstrated the feasibility of embedding smart functionalities such as self‑healing coatings, bioactive surfaces, and autonomous repair mechanisms directly during manufacture. The AI‑Aided Engineering Platform is operational, integrating a semantic knowledge base, multi‑physics simulations, and machine learning for automated process planning, recipe validation, and lifecycle optimisation, enabling up to 50% faster design iteration and 30% shorter manufacturing lead times.

Scientifically, WISE advances the state of the art in multi‑scale, multi‑material manufacturing, demonstrating the integration of additive, subtractive, and functionalisation processes in a single coordinated platform. Economically, it offers a scalable route to high‑value, customised components, strengthening European competitiveness in strategic sectors. Societally and environmentally, it supports EU sustainability goals through energy‑efficient processes, reduced waste, and extended product lifetimes, while embedding inclusiveness and workforce upskilling. To ensure further uptake and success, several needs are identified: continued research to refine process stability, material compatibility, and long‑term functional performance under operational conditions; extended demonstration campaigns in industrial environments to validate reliability, throughput, and cost‑effectiveness at scale; targeted actions to secure access to markets and finance, including engagement with early adopters and investors; robust commercialisation strategies supported by clear IPR management to protect and exploit the project’s innovations.