Sensor based adaptive laser micromachining using ultrashort pulse lasers for zero-failure manufacturing

Project Information

ADALAM

Grant agreement ID: 637045

DOI

10.3030/637045

Project closed

EC signature date 13 November 2014

Start date 1 January 2015

End date 30 June 2018

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Information and Communication Technologies (ICT)

Total cost

€ 4 201 510,00

EU contribution

€ 3 764 635,00

Coordinated by

UNIMETRIK SA
Spain

Periodic Reporting for period 3 - ADALAM (Sensor based adaptive laser micromachining using ultrashort pulse lasers for zero-failure manufacturing)

Reporting period: 2017-01-01 to 2018-06-30

Summary of the context and overall objectives of the project

Miniaturization, advanced high performance materials and functional surface structures are all drivers behind key enabling technologies in high added value production. It is in such areas that ultrashort pulse lasers have enabled new machining concepts, where the advantages of laser machining are combined with a quasi non-thermal and therefore mild process, which can be used to machine any material with high precision.
However, an important obstacle that hinders the full exploitation of the unique process characteristics is the lack of a smart/adaptive machining technology. The laser process in principle is very accurate, but small deviations - e.g. in the materials to be processed - can compromise the accuracy to a very large extent. Therefore, feedback systems are needed in order to keep the process accurate
For that reasons, ADALAM is developing an adaptive laser micromachining system, based on ultrashort pulsed laser ablation and a novel depth measurement sensor, together with advanced data analysis software and customized calibration procedures.
The availability of an adaptive machining process associated to an inline distance measurement system in ADALAM is aimed at industrial application and can also serve as a development tool for future smart laser based manufacturing systems. The calibration of the measurement system as well as the positioning machine regarding aspects as traceability and certification will be a central part of the project objective.
The ADALAM project will deliver convincing evidence to the industry of the benefits of the use of adaptive ultra-short pulsed laser based manufacturing systems and its monitoring/control with in-line dimensional metrology. So, within the project three industrial applications are being developed:
• micromachining process to process deviations
• micromachining process to defect detection and removal present on a workpiece
• texturing process in shape and position of complex 3D shapes

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 two first years of the ADALAM project, each WP has developed the following work:
• WP1 Project Management: Periodic coordination meetings were scheduled, where every WP leader summarize the status of the WP and main achievements. At deliverable level, every document was internally revised for a no-expert partner to ensure that the content may be understood for general public. Also, a wiki space has been created for documentation management.
• WP2 Inline topography sensor: In WP 2 five modules needed for the data acquisition and to implement the adaptive loop, have been designed, manufactured and tested. In addition, a complete off-line measuring system, assembled from these modules has been tested and characterized.
• WP3 Adaptive laser micromachining system: The main objective achieved during this period has been the integration of the topography sensor. Furthermore, WP3 partners have been working on the concept of the alignment system (Beam measurement system) and field calibration system, contributing to the second objective of the WP. Finally, in relation to the third objective, initial design of the control software has been started.
• WP4 System Calibration, Traceability and Certification: Dedicated dimensional artifacts have been designed for systems characterization. Then, as a function of systems properties and following referenced standards, procedures for characterization and final calibration are being defined.
• WP5 Active Micromilling: This WP defined all the requirements for laser based micromilling of steel and hardmetal and based on that the milling toolkit has been created. Then, the requirement and technical specifications definition, as well as components tests have been carried out and the laser source delivered after some design and components adjustments.
• WP6 Defect detection and removal on wafer carriers: The WP started with the definition of the defect spectrum and its metrological characterization. Then, work has been focused on the automatic pointcloud software the laser process for defect removal. The tasks on the point cloud software and laser process are still in progress.
• WP7 Recognition and Texturing of Complex Tool Features: WP started with definition of the product, feature spectrum, the metrological characterization and the definition of the process requirements. Afterwards, the work has been focused on the customization of the point-cloud analysis software and communication method for the texturing process, in collaboration with WP6. A laser process for hardmetal texturing using oblongs and dimples was developed for the available 10 ps laser.
• WP8 Dissemination and exploitation: Project website, Twitter and LinkedIn are regularly updated; posters, leaflet and roll-up were created. The initial business plans are defined at individual level; joint business models (based on expected results) in consideration.

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)

ADALAM is developing a new approach for zero defect manufacturing that is based on three main topics:
1. In-line topography sensor for adaptive process.
2. Adaptive laser micromachining system: Integration of the laser source, inline topography sensor and automation of the information extraction for laser process adaptation to the application scenario.
3. Customized characterization and calibration methodologies ensuring system performance and accuracy
There are five main impact topics addressed:
A. Reinforced capacity to manufacture high-quality and innovative products and to penetrate new application areas
The integration of all the elements being developed in the project will allow the generation of a high quality and flexible laser based machine enabling the zero failure manufacturing.
B. Strengthened market position of European producers of laser-based manufacturing equipment, their suppliers and of the users of the equipment
The developed solution integrates the knowledge coming from all the value chain, end-users, technology providers and machine producers. Also, the implementation of innovative approaches such as the topography sensor and software analysis for monitoring and enable the adaptive process to improve the European laser-related market. . Furthermore, each of the partner expects to generate a new product from the project, improving their presence in the market with innovative solutions.
C. Increased capability for better and faster reaction to market changes by being able to use holistic global and local optimization algorithms in a collaborative value chain
ADALAM solution is highly customizable depending on the case: the laser source depending on the material and action to be developed, the data acquisition and pointcloud analysis software, large working volume for different part sizes,…
D. Environmental impacts
The adaptive laser manufacturing will be able to reduce considerably the number of rejected parts leading to zero-failure process. Herewith a substantial decrease of the overall material and resource utilization will be achieved. The project is also addressing machine load and operating costs, maintenance, down time and energy utilization in the texturing case and less energy consumption in households all over the world as well as the usage of a lighting solution free of toxic chemicals in the defect carrier removal case.
F. Socially important impacts
The implementation of such technologies in the industry generates a market demand of high qualified workers, contributing to the decrease of the young unemployment rate.

ADALAM project logo

ADALAM solution concept