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.
| Web resources: |
https://cordis.europa.eu/project/id/862017
https://www.grade2xl.eu/ |
| Start date: | 01-03-2020 |
| End date: | 31-08-2024 |
| Total budget - Public funding: | 9 752 666,00 Euro - 7 910 280,00 Euro |
Original description
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.
Status
SIGNEDCall topic
DT-NMBP-19-2019Update Date
27-10-2022
05/10/21 - 14:19
Additive Manufacturing Design Contest for Young Engineers 2021 - Apply now!
During the annual conference Meeting Materials, organized by M2i, the Grade2XL project will organize an open Additive Manufacturing Design Contest for young engineers as part of the Grade2XL project.
GOT WHAT IT TAKES?
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Are you enrolled in a Bachelor, Master or PhD degree program at a European university? Or are you a young professional who is still under the age of 35 years on 14 December 2021?
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Do you have an idea for a 3D printed component that can be made with the wire arc additive manufacturing technology?
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Are you passionate about technology and want to see your ideas take shape?
GRADE2XL
The Design Contest is part of the Horizon 2020 project Grade2XL. This project will demonstrate the potential of multi-material wire arc additive manufacturing (WAAM) for large structures. Grade2XL will deliver multi-material products of superior quality and performance, cut lead times by up to 96% and enable massive savings for the maritime, energy and industrial machinery sectors. The Grade2XL consortium is led by M2i and gathers 21 partners from eight European countries, top innovators in the field of wire arc additive manufacturing.
CRITERIA
The following criteria will shape the selection process:
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Novelty: new geometry, impossible to manufacture with conventional processes;
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Functionally graded: showing added value of multi-material composition, i.e. different properties at different locations;
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Purpose: the design should be intended for a real engineering application.
SCORING CRITERIA
There is a maximum score of 10 points:
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Novelty: The extent to which the proposed design is a new geometry impossible to manufacture with conventional processes. Score 0-3
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Functionally graded: The extent to which the proposed gains (material or financial savings) when a multi-material approach is used, i.e. different properties at different locations. Score 0-3
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Purpose: The extent to which the design is suitable for an existing engineering application. Score 0-3
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Bonus point: Potential to impact the industry i.e. transferability of the approach towards other applications and sectors. Score 1
JURY
The Jury consist of five experts working in the field of WAAM, in academic and industrial organisations which are at the forefront of WAAM.
THE PRIZE
One winner/winning team will have their part manufactured at RAMLAB in Rotterdam. If the designed part is heavier than 20 kg, a representative component of up to 20 kg will be printed. The winner/winning team will be selected via a blind procedure.
DEADLINE
The submission deadline is 19 November 2021. The winner will be announced during the M2i "Meeting Materials" Conference on 14 December 2021.
APPLICATION
Make sure you download one of the application forms on the Grade2XL website available here. In the form you will find all information necessary for submitting your design.
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