Project description
Healing the flaws of additive manufacturing
Additive manufacturing (AM) is transforming industrial production, but process-induced defects still limit its use in safety-critical aerospace and energy applications. Supported by the Marie Skłodowska-Curie Actions programme, the I-HEAL AM project aims to overcome this barrier by developing an AI-driven ‘see-think-act-verify’ workflow for Inconel 718, a high-performance superalloy. Unlike passive monitoring systems, this new system introduces a fully autonomous closed-loop process that detects anomalies in real-time and performs surgical, in-situ repairs. By combining deep learning with dynamic beam modulation and targeted recoating strategies, the project achieves a true ‘zero-defect’ standard. This breakthrough not only extends the reliability of critical components but also strengthens Europe’s manufacturing leadership, providing a data-rich digital twin to secure industrial excellence.
Objective
"Laser powder bed fusion (PBF) additive manufacturing (AM) is hampered by process-induced defects that degrade mechanical properties, preventing its use in safety-critical applications. Current in-situ monitoring systems are reactive, offering passive data logging but no autonomous, real-time correction. The research targets Inconel 718, an aerospace superalloy notoriously prone to such defects.
The I-HEAL AM project will overcome this bottleneck by developing a truly autonomous “see-think-act-verify” workflow for proactive, in-situ healing with a <10-second overhead per layer. Its novelty is a fully closed loop of intelligent, surgical intervention and verification. A two-stage AI processes multi-modal sensor data: an unsupervised autoencoder flags anomalies, and a supervised CNN performs precise characterization. A custom software architecture then executes adaptive healing, including dynamic beam modulation for minor porosity and a novel 'Partial Recoat and Healing' strategy. This targeted approach minimizes heat input and detrimental residual stresses. The unique in-situ verification step confirms each repair, creating a data-rich “digital twin” for unprecedented part qualification. The system's success will be validated on an industrial demonstrator, improving functional performance.
This project will establish a new benchmark for ""zero-defect"" manufacturing, enabling the qualification of reliable AM parts for European aerospace and energy sectors. A strategic secondment at the IAM@PoliTO, Politecnico di Torino, will advance the project’s science by integrating the methodology with the host's deep AM expertise to generate fundamental new insights into in-situ healing. For the researcher, this fellowship provides unique skills, paving the way for a leadership role in advanced manufacturing."
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology electrical engineering, electronic engineering, information engineering electronic engineering sensors
- engineering and technology mechanical engineering manufacturing engineering additive manufacturing
You need to log in or register to use this function
Keywords
Project’s keywords as indicated by the project coordinator. Not to be confused with the EuroSciVoc taxonomy (Fields of science)
Project’s keywords as indicated by the project coordinator. Not to be confused with the EuroSciVoc taxonomy (Fields of science)
Programme(s)
Multi-annual funding programmes that define the EU’s priorities for research and innovation.
Multi-annual funding programmes that define the EU’s priorities for research and innovation.
-
HORIZON.1.2 - Marie Skłodowska-Curie Actions (MSCA)
MAIN PROGRAMME
See all projects funded under this programme
Topic(s)
Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.
Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.
Funding Scheme
Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
HORIZON-TMA-MSCA-PF-EF - HORIZON TMA MSCA Postdoctoral Fellowships - European Fellowships
See all projects funded under this funding scheme
Call for proposal
Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.
Procedure for inviting applicants to submit project proposals, with the aim of receiving EU funding.
(opens in new window) HORIZON-MSCA-2025-PF
See all projects funded under this callCoordinator
Net EU financial contribution. The sum of money that the participant receives, deducted by the EU contribution to its linked third party. It considers the distribution of the EU financial contribution between direct beneficiaries of the project and other types of participants, like third-party participants.
5230 Odense M
Denmark
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.