From aeronautics to oil & gas, complex metal parts embrace major challenges across their lifecycles from the green field intensive manufacturing to the numerous maintenance and repairing operations worldwide distributed. The synergic combination of additive and subtractive processes could overcome individual shortcomings, going beyond the simple succession of steps. 'Plug and produce' modular approach is a key factor to success for such hybridization. In this scenario, 4D delivered 4 disruptive breakthroughs:
•A set of four elementary modules specifically designed for AM that embed the control and monitoring systems which can be integrated on new or existing concepts of machines
•A new concept of CNC, constituting a high level sw layer which can be integrated on the top of commercial CNCs
•A validated process model to fully exploit the synergistic interactions among elementary processes
•A dedicated 4D Engineering CAD/CAE/CAM Platform, which covers the lifecycle of the reference product family where multiple processes and hybrid resources are integrated for the (re)manufacturing stage.
Innovation was be physically demonstrated at three possible levels of hybridization:
•Modules - Small hybrid modules, integrated on new special machines, focusing on portable units for certified in-situ repair operations
•Hybrid Machines – Hybridization on existing robots and machines
•Production lines - Hybridization of a flexible production line focusing on new concepts for AM mass production
4DHybrid’s ground-breaking target is to reduce by 30% the lifecycle cost of finished components manufactured by 4DHybrid modules, compared to current market prices of AM components.
4DHybrid want to improve the European leadership in AM technologies by exploiting results from past and on-going projects (mainly Borealis and Corsair), involving leading companies in the metal working sector (PE part of Prima Industrie, Comau, Siemens), leverage innovation by European SMEs (3D-NT, Iris, Ramteid) and target the global market by involving in the consortium end users and potential customers from America and Africa (and Asia in the Interest Group) with the support in communication and dissemination by MCI-Benelux.
4DHybrid wishes to strengthen the first worldwide AM cluster where all the major players and initiatives will be partnered to promote global actions to support the industrially structured adoption of new hybrid technologies.
