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

Summary

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.

More information
Web resources: http://www.integraddeproject.eu/
https://cordis.europa.eu/project/rcn/218516/factsheet/en
Start date: 01-10-2018
End date: 31-03-2023
Total budget - Public funding: 12 716 173,00 Euro - 12 716 173,00 Euro
Call topic: Pilot lines for metal Additive Manufacturing (IA 50%) (DT-FOF-04-2018)
Twitter: @Integradde
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This is a set of Specific Objectives and Research & Innovation Objectives that is subject to a consultation in preparation of the Made In Europe Partnership.  For more guidance about the consultation, please see www.effra.eu/made-in-europe-state-play.

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Intelligent data-driven pipeline for the manufacturing of certified metal parts through Direct Energy Deposition processes
Latest news
Raquel Carro
08/04/21 - 10:10
Registration is now open for INTEGRADDE Online trainings!

Join the INTEGRADDE training sessions: Additive Manufacturing for Manufacturers and Final Users

The INTEGRADDE consortia has come together to offer you a 2-part online training session on June 25th and July 2nd on Additive Manufacturing.

This is an optimal way of transferring the knowledge and know-how obtained through the development of the project activities to the entire sector, including academia, professionals and public authorities.

The main objectives of these trainings are, on one hand, present the benefits for the industry of the technologies developed within project and, on the other hand, boost the acceptance and integration of the project results in the Advanced Manufacturing value chain.

This is a one-of-a-kind opportunity for entities and professionals in the sector to get first-hand information on how to apply these technologies, gain confidence about their use and stay at the forefront of the industry´s future. 

On the agenda: 

The first session will take place on June 25th and will be oriented to manufacturers. The main topics covered will be:

  • Design for Additive Manufacturing
  • Material procurement
  • Process with focus on WAAM and Laser
  • Post processing

The second session will take place on July 2nd and will be oriented to final users. The main topics covered will be:

  • General introduction to Additive Manufacturing
  • Market of Additive Manufacturing and expectations 
  • Modelling 
  • HSE (Health, safety and environmental protection in the manufacturing sector)
  • Standardization 
  • Quality and Certification 

Both sessions, organised by Bureau Veritas, will be taught by experts from top-level organisations and companies, among them:

  • ESI Group 
  • MX3D 
  • German Institute for Standardization (DIN)
  • AIMEN Technology Centre
  • Bureau Veritas Group
  • Laboratory for Manufacturing Systems & Automation at University of Patras

Do not miss this opportuniy and BOOK YOUR TICKET here!

Join the INTEGRADDE community for more events and opportunities in Advanced Manufacturing. 

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Raquel Carro
01/02/21 - 13:19
An Open Pilot Line at IREPA LASER

IREPA LASER is an industrial research and development company specialized in laser processes and materials, with a laser machine base including over 20 devices to support all companies in their needs.

The main service is to offer customers tailored industrial solutions to support them in their product development and manufacturing engineering projects. This service is focused on three main skill areas: Additive Manufacturing, surface functionalization and welding. IREPA LASER is also a laser training centre and can train individuals in the use of laser technology.

IREPA LASER is involved within INTEGRADDE project for the development of 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. An open-pilot line will be implemented at IREPA LASER, which will allow a continuous validation and deployment of specific developments towards industrialization.

The general INTEGRADDE concept and end-to-end the solution is being deployed at IREPA facilities to test and review as early adopter of this manufacturing methodology. Data collected from different steps are implemented through the digital thread with the final aim to improve the quality of the parts manufactured.

The development of this concept uses of the equipment features of IREPA LASER.

A machine is dedicated to DED-powder (MAGIC system) with 2 lasers (IPG YLR500, and IPG DLR2000), the original MacroCLAD head from IREPA LASER, and a powder feeder from MEDICOAT.

A new hardware has been recently implemented at IREPA LASER. This new robotic system consists of 2 robots, one of which is installed on a linear 5m axis, a rotary table able to support 3T. 2 fibre lasers (IPG laser YLS) bring their laser beam to the DED-powder and DED-wire heads. Profinet network is used to connect and control all this equipment. This novel machine has been designed in order to work on a large scale parts (up to 5m long), with the selected two processes: DED-powder and DED-wire.

Using previous existing LMD-p infrastructure, several developments on process window development, monitoring and control have been carried out. Particularly, efforts have been focused on data collection from CNC and image-based process monitoring information. Data are collected from process sensors (such as image-based data from an NIT camera, temperature) and CNC positions synchronously during the additive manufacturing process. These datasets have been processed, in collaboration with AIMEN, NIT, ATOS and CEA, to generate a 3D representation of the parts being built.

Concerning the digital thread, IREPA has recently migrated on a new CAD-CAM software: SIEMENS NX with the ‘multiaxis deposition module’ for DED machine programming. In collaboration with the partner ‘University of Coimbra’, the use of the AML format in development.

Process development is carried out by using the two DED processes: DED-p and DED-w.

Concerning the DED-w, the PRECITEC Head named ‘Coax Printer’ is used. The upgraded version of this head has been recently received and implemented. It allows recording the interaction between beam-wire-substrate during the deposition with a coaxial vision in order to get more data for the control process.

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Raquel Carro
19/11/20 - 10:53
Standardization in INTEGRADDE

In research projects, especially when public funding is provided, the effective, economic usability of the results is increasingly in the focus. Research projects must therefore be holistically and long-term oriented. For this purpose, DIN offers many years of expertise to provide optimum support for the market transfer and dissemination of innovative results from research and development.

In INTEGRADDE, DIN is the partner for questions concerning standardization. DIN coordinates the standardization activities of the project. These activities comprise the knowledge transfer regarding standardization, the development of an overview of the current standardization landscape in the subject area AM as well as the development of accompanying standardization measures.

To foster the knowledge transfer a special standardization training was developed aiming to enable the project partners to develop and pursue joint standardization activities.

The overview of the current standardization landscape provides a detailed research on relevant standardization committees and corresponding standards.

In the case of INTEGRADDE, it quickly became clear that ISO/TC 261 "Additive Manufacturing" is trend-setting in AM and that close cooperation should be targeted.

Due to the very different knowledge base in INTEGRADDE about standardization DIN has developed a standardization training especially for the INTEGRADDE project. The aim of the training was to provide knowledge enabling the project partners to develop and pursue joint standardization activities. Furthermore, the training emphasizes the high relevance of standardization for AM and is meant to motivate the project partners to follow current developments in standardization committees as well as to document and disseminate the knowledge acquired in INTEGRADDE in the long term. The training is divided into the following five chapters: Meaning, structure, integration, AM, follow-up. Each chapter has its own conclusion with the most important information in order to realize an easy understanding and the highest possible absorption of the knowledge.

The training provides information on why it is important to push the issue of standardization both from the beginning and continuously and what the benefits of standardization are. This is followed by an explanation of the basic principles of the working method and the underlying process. The third chapter presents the possibilities for participation and gives an assessment of the resources required for participation.

In the chapter specifically focusing on AM, the most important standards are listed and the standards research carried out is explained. In addition, the structure of the standardization committees in the area of AM is explained before finally reaching a conclusion with the most essential information.

 

After these cornerstones were laid, the actual standardization started. Challenges faced by the project partners due to gaps in standardization were assessed with the help of a two day workshop. On day one the project partners were asked to position themselves within the INTEGRADDE process as well as to identify and to prioritize current challenges with regard to standardization. On the second day of the workshop the challenges were compared to current and planned standardization projects of ISO/TC 261. These comparisons have been discussed and it was determined in which projects INTEGRADDE should participate or comment. The following key issues of INTEGRADDE for standardization could be identified: 

·        Digital thread

·        Quality assessment (operator, machines, process)

·        Software interoperability

·        Process safety

·        Testing (software, non-destructive, destructive)

·        Properties(feedstock conditions, material, finished parts (e.g. defects))

·        Design methods

·        Terminology

Based on these results a common standardization strategy for the INTEGRADDE project has been prepared. Especially the standardization idea of the "digital thread" for which there is currently no current or planned standardization project is of great importance for the INTEGRADDE project. For this reason, the project is currently striving for close cooperation with ISO/TC 261/WG 4 "Data and Design". With the development of the standardization strategy, an important milestone was accomplished regarding standardization. The further implementation of this strategy will be coordinated and supported by DIN.

As steps in standardization DIN will continue to pursue a close collaboration between the standardization bodies and INTEGRADDE.  One step will be to contribute to the assessed standardization projects. DIN further will identify the responsible groups within ISO/TC 261 for the remaining standardization ideas and check how these can be addressed best.

http://www.integraddeproject.eu/590/standardization_in_integradde

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08/04/2021 09:42:42 - Integradde Project -@Integradde
O Porriño, España
📢The #integraddeproject presents its #AdditiveManufacturing training sessions! 🗓️AM for manufacturers: June 25th at 9:00 AM - 3:00 PM CEST 🗓️AM for final-users: July 2nd at 9:00 AM - 3:00 PM CEST 👉 Register today and access #AM free trainings: [URL] [Go to tweet]

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