1. Project
  2. BOREALIS

Borealis - the 3A energy class Flexible Machine for the new Additive and Subtractive Manufacturing on next generation of complex 3D metal parts.

Summary

Borealis project aims to develop a completely new concept of additive manufacturing machine: the solution is conceived as integration of a new architecture, a new manufacturing processes, a specific monitoring control infrastructure. Borealis project presents an advanced concept of machine for powder deposition and ablation processes that integrates 5 AM technologies in a unique solution. The system is specifically conceived for industrial sectors that suffer extremely high manufacturing costs because of part complexity and low volumes and the prohibitive cost of raw material. As a result, Borealis focuses on the Medtech, Aerospace and Automotive sectrors as major target. More over, the challenge of Borealis is to allow the production of big metal components using the AM process and trough a novel AM machine able to produce large and complex parts with unprecedented throughput and efficiancy, in true net shape, with closed loop controlled and certified quality. Borealis idea results from a consortium composed by the excellence of developers of worldwide recognized laser machines and advanced material processing together with the highly precision and flexible mechatronic designers. These two big clusters decided to join their expertise and focus on new manufacturing challenges coming from complex product machining in the field of aerospace, medtech and automotive represented by major partners in the market. Borealis project targets a TRL 6 and provide as outcome of three years work two complete Borealis machine in two dimensions, a lab scale machine and a full size machine, which are foreseen to be translated into industrial solution by 2019.

More information
Website: http://www.borealisproject.eu/
Duration: 36 months
Start date: 01-01-2015
End date: 31-12-2017
Number of participants: 16
Total budget - EC contribution: 7986625 Euro - 5968875 Euro
Call topic: Manufacturing processes for complex structures and geometries with efficient use of material (FoF.NMPB.2014.2)
Instrument: DEMO-targeted collaborative project
Location
Characteristics

Challenges - (13)  

  1. Challenges
    1. Manufacturing the products of the future
      1. Novel materials
      2. Complex structures, geometries and scale
      3. Customised products
      4. Resource efficient, sustainable products
    2. Economic sustainability
      1. Realising reconfigurable, adaptive and evolving factories capable of small scale production
      2. High performance production, combining flexibility, productivity, precision and zero-defect while remaining energy-efficient
    3. Environmental sustainability
      1. Optimising the exploitation of materials in manufacturing processes
        1. Reduction of scraps (defective workpieces) and reworks
      2. Co-evolution of products-processes-production systems

Technologies and enablers - (11)  

  1. Technologies and enablers
    1. Advanced manufacturing processes
      1. Additive manufacturing
      2. Photonics-based materials processing technologies
      3. Shaping technology for difficult to shape materials
    2. Mechatronics for advanced manufacturing systems
      1. Control technologies
      2. Cognition-based intelligent features within machinery and robots
      3. Condition and performance monitoring
    3. Manufacturing strategies
      1. Innovation

Digitalisation pathways - (No information available)  

Research priorities - (12)  

  1. Research priorities
    1. Domain 1: Advanced manufacturing processes
      1. Sub-Domain 1.1 Processing novel materials and structures (into products)
        1. RP 1.1 Manufacturing for custom made parts
      2. Sub-Domain 1.2 Complex structures, geometries and scale
        1. RP 1.6 Material efficient Manufacturing processes
        2. RP 1.9 Integrated manufacturing processes
        3. RP 1.10 Manufacturing of high performance flexible structures
    2. Domain 2: Adaptive and smart manufacturing systems
      1. Sub-Domain 2.1 Adaptive and smart manufacturing devices, components and machines
        1. RP 2.1 Flexible and reconfigurable Machinery and Robots
        2. RP 2.6 Mechatronics and new machine architectures for high performance and resource-efficient manufacturing equipment

Diverse - (No information available)  

Results
Demonstrators
Organisations
Contacts
Paolo Calefati

Paolo Calefati
Eleonora Marino

Eleonora Marino
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