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Intelligent data-driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition processes

Project description

Novel methodology for metal part construction

Breakthroughs in additive manufacturing and metal part construction have led to high demand for optimisation solutions that would increase efficiency throughout the production process. The EU-funded INTEGRADDE project will meet this need by introducing a digital manufacturing solution that would allow the efficient implementation of automation and holistic data management throughout the additive manufacturing chain. This methodology would guarantee high levels of quality, durability and efficiency for metal parts by using direct energy deposition across the chain, optimising processes and making predictions using AI-simulated models, reducing defects and allowing for integrity throughout the workflow.

Objective

The industrialisation of Additive Manufacturing (AM) requires a holistic data management and integrated automation. INTEGRADDE aims to develop an end-to-end Digital Manufacturing solution, enabling a cybersecured bidirectional dataflow for a seamless integration across the entire AM chain.

The goal is to develop a new manufacturing methodology capable of ensuring the manufacturability, reliability and quality of a target metal component from initial product design via Direct Energy Deposition (DED) technologies, implementing a zero-defect manufacturing approach ensuring robustness, stability and repeatibility of the process. To achieve this aim, INTEGRADDE addresses following key innovations:
- Development of an intelligent data-driven AM pipeline.
- Combination of automatic topology optimisation algorithms for design, multi-scale process modelling, automated hardware-independent process planning, online control and distributed NDT for the manufacturing of certified metal parts.
- A self-adaptive control is adopted focused on the implementation of non-propagation of defects strategy. Moreover, Data Analytics will provide a continuous refinement by acquiring process knowledge to assist in the manufacturing of new metal components, improving right-first-time production by adopting a mass customization approach
- Cybersecurity ensures data integrity along the AM workflow, providing a novel manufacturing methodology for the certification of metal AM parts.

INTEGRADDE implements a twofold deployment approach for the pilot lines: both in application-driven at five industrial end-users (steel, tooling, aeronautics, and construction) and open-pilot networks at RTOs already owning AM infrastructure (AIMEN, IREPA, CEA, WEST). This will allow a continuous validation and deployment of specific developments towards industrialization, boosting definitive uptake of AM in EU metalworking sector.

Call for proposal

H2020-NMBP-TR-IND-2018-2020

See other projects for this call

Sub call

H2020-NMBP-FOF-2018

Coordinator

ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE
Net EU contribution
€ 1 160 625,00
Other funding
€ 0,00

Participants (27)