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
Web resources: http://www.borealisproject.eu/
https://cordis.europa.eu/project/rcn/193449/factsheet/en
Start date: 01-01-2015
End date: 31-12-2017
Total budget - Public funding: 7 986 625,00 Euro - 5 968 875,00 Euro
Call topic: Manufacturing processes for complex structures and geometries with efficient use of material (FoF.NMPB.2014.2)
Cordis data

Original description

Borealis project presents an advanced concept of machine for powder deposition additive manufacturing and ablation processes that integrates 5 AM technologies in a unique solution. The machine is characterized by a redundant structures constituted by a large portal and a small PKM enabling the covering of a large range of working cube and a pattern of ejective nozzles and hybrid laser source targeting a deposition rate of 2000cm3/h with 30 sec set-up times. The machine is enriched with a software infrastructure which enable a persistent monitoring and in line adaptation of the process with zero scraps along with number of energy and resource efficiency optimization policies and harvesting systems which make the proposed solution the less environmental invasive in the current market.
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 will 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.

Status

SIGNED

Call topic

FoF-02-2014

Update Date

07-11-2021
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Economic sustainability Flexibility Environmental sustainability Material efficiency Waste minimisation
Co-evolution of products-processes-production systems (‘indu... Reduction of energy consumption (in %) Reduction of CO2 emissions (in %) Reduction of waste (in %) Reduction of material consumption (in %)

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Manufacturing the products of the future Novel materials Complex structures, geometries and scale
Customised products Resource efficient, sustainable products Domain 2: Adaptive and smart manufacturing systems

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Advanced material processing technologies Additive manufacturing Photonics-based materials processing technologies Shaping technology for difficult to shape materials
Mechatronics and robotics technologies Control technologies Intelligent machinery components, actuators and end-effectors Measurement, sensing, condition and performance monitoring t...

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Performance characteristics