Project description
A 3D-printing method for high-performance large structures
Large engineering structures like turbines, bridges or industrial machinery are still manufactured by traditional processes such as forging and casting. These processes do not allow engineers to control material properties locally in order to achieve anti-corrosion or hardness functions, only at the exposed or loaded locations. The EU-funded Grade2XL project will tap into the potential of wire arc additive manufacturing. This method combines high printing rates with the ability to control material properties down to the nanoscale, enabling the design of strong and durable engineering structures. The project is expected to deliver devices of superior quality and performance, cut lead times by up to 96 % and unlock massive cost savings for the maritime and energy industries.
Objective
Large engineering structures like turbines, bridges or industrial machinery are still manufactured by traditional processes such as forging, casting or by machining from solid blocks. These processes do not allow local control of material properties to achieve a specific function like anti-corrosion or hardness. To meet the functional specifications, engineers must operate within a limited range of design options, with high “buy-to-fly” ratios and long lead times.
Unlike any other metal AM technology, wire arc additive manufacturing (WAAM) produces fully dense metallic structures with no porosity. WAAM is also unbeatable in terms of production times, making it uniquely suited for large and functionally demanding engineering structures.
In Grade2XL, we will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large scale structures. The high printing rate of WAAM, combined with the ability to control material properties down to the nanoscale, will allow us to build strong and durable engineering structures. Grade2XL will deliver multi-material products of superior quality and performance, cut lead times by up to 96% and enable massive cost savings for the maritime and energy industry, as well as for industrial machinery. These outputs will rapidly roll out to other sectors with similar key performance indicators and become an attractive investment opportunity for SMEs. This project will strengthen Europe’s capacity to drive manufacturing innovation globally and withstand growing competition from Asia.
Fields of science
Keywords
Programme(s)
Funding Scheme
IA - Innovation actionCoordinator
2628 CS Delft
Netherlands
See on map
Participants (21)
3089 JW ROTTERDAM
See on map
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.
9000 Gent
See on map
2628 CN Delft
See on map
75015 PARIS 15
See on map
2800 Kongens Lyngby
See on map
59067 Hamm
See on map
2952 AT Alblasserdam
See on map
1831 Diegem
See on map
6534 AD Nijmegen
See on map
50-370 Wroclaw
See on map
75015 Paris
See on map
3320 Velenje
See on map
75008 Paris
See on map
49280 La Seguiniere
See on map
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.
86153 Augsburg
See on map
9301ZR Roden
See on map
B90 8BG Solihull
See on map
Legal entity other than a subcontractor which is affiliated or legally linked to a participant. The entity carries out work under the conditions laid down in the Grant Agreement, supplies goods or provides services for the action, but did not sign the Grant Agreement. A third party abides by the rules applicable to its related participant under the Grant Agreement with regard to eligibility of costs and control of expenditure.
3351 NL PAPENDRECHT
See on map
59 400 Jawor
See on map
92400 COURBEVOIE
See on map
44340 Bouguenais
See on map