Optician2020 has developed distributed manufacturing assets in mini-factories clustered in urban areas combining short series manufacturing technologies and ICT tools for design, process automation and on-line real time delivery management of personalised spectacles, a fashionable product combining health prescription, functional performance and aesthetical requirements. The key enabling technologies deployed are: - additive manufacturing, for polymeric and metallic frames - advanced coating technologies, for short series lens coating - automated procedures, for personalisable frames catalogue design - scanning devices, for end-user anthropometric data capture ICT tools are used to improve the efficiency, adaptability and sustainability of the production systems and their integration within the proximity mini-factory business model. It requires continuous change of processes related to the management of distributed manufacturing assets and to the personalised manufacturing of spectacles in which the consumer can select frame materials and also finishings both in frame and lenses. Optician2020 has demonstrated the feasibility of this business model based on close-to-optician mini-factories by showing: - The spectacles personalisation flexibility, developing a catalogue of at least 12 models in spectacles for 450 users. - The mini-factories flexibility and re-configurability with an agile procedure for adding new local manufacturing facilities to the open virtual network. - The time-to-market reduction up to 65% and production cost reduction of 40% with respect to conventional methods. The exploitation will start one year after the completion of Optician2020. A maximum initial impact of 25.000 spectacles can be obtained with two initial clusters of networked minifactories working efficiently for a group of 12 opticians in each cluster. It is expected to expanding the number of mini-factories with 10 more EU-based clusters.
|Total budget - Public funding:||5 770 513,00 Euro - 3 614 999,00 Euro|
|Call topic:||Mini-factories for customised products using local flexible production (FoF.NMP.2013-6)|
Comment: According to data provided by Optician partners in the Consortium, ~20%-40% of spectacles are stocked up with conventional production systems that most of the times are never selled and can be considered waste. Based on that figure, 1.3 spectacles (30% of stock) should be produced in standard manufacturing process in comparison with the Optician 2020 production system. Besides, additive manufacturing technologies improve the energy consumption and raw material output/input ratio of traditional processes
Comment: Inks and lacquers used in lens coating, currently applied by dip-coating, a procedure generating contaminated residues coming from the dip tanks every time that their content is refreshed. Optician2020 will use suitable processes for short series coating based on spin coating that deposits the exact amount of necessary ink.
Comment: Demonstration activities have shown that the manufacturing of personalized products by means of 3D printing technologies and local manufacturing can reduce the eco-cost up to a significant 50-62% in the best case when compared to traditional processes.
- Design and 3D personalized frame model creati...
- 3D personalised spectacles calculation ...
- User’s head and facial capture device ...
- Polymeric frame AM manufacturing and finishin...
- Metallic frame AM manufacturing and finishing...
- Personalized lenses generation and coating pr...
- ICT-based mini-factories platform management ...
- Industrial scalability studies