DREAM stands for “Driving up Reliability and Efficiency of Additive Manufacturing” and it was funded under Horizon 2020 Factories of the Future Initiative with an EU contribution of more than 3,2 millions of euros to implement a disruptive photonics technology to enable the 4th Industrial revolution through the implementation of laser-based metal Additive Manufacturing.
The specific aim of DREAM was to significantly improve the performances of laser Powder Bed Fusion (PBF) of titanium, aluminium and steel components in the following terms: weight reduction, production speed increase, material cost reduction, process productivity increase and fatigue test increase with a sustainable Life Cycle Approach. In addition, DREAM targeted the detection and removal of contaminants from raw powders for PBF.
The reduction of part weight has been fully achieved for all the user cases, and consequently material cost has been effectively moderated below the target. Impressive outcomes were obtained for productivity and production speed, well above the set goals. The same is true for fatigue strength, thanks to a successful combination of the actions on powder purity and on process control. As for the quantification of cross-contamination, the project led to the proposal of a robust statistical procedure that could be easily implemented into an in-line quality control system, as well as proposed to standardization committees. At present, the approach is being patented.
Through innovations in part modelling, materials and additive processing, DREAM added competitiveness at all steps of the manufacturing chain, so that each of the Consortium partners benefited from a reinforced industrial leadership, consisting in the offer of: more efficient additive manufacturing systems; optimized on-demand services for the production of cost-effective component, novel engineering design services combining topology optimization and design; more lightweight and reliable products.
The environmental impact of the DREAM project relied in fostering the widespread use of a manufacturing process that is clean, environment-friendly and cost-competitive. DREAM also contributed in minimizing waste, the use of hazardous substances and resource consumption.
DREAM brought about a decrease in the use of many resources: raw material, cutting fluids, installed power in the workshop, energy.
In terms of society, DREAM project will benefit employment growth and promote a healthy competitiveness in the EU area, as AM influences numerous industrial sectors all over Europe.
Moreover, the project aimed at producing more affordable biomedical device with an immediate impact on the surgical practice and, hence, on the quality of life of patients.
