Periodic Reporting for period 1 - KRAKEN (Hybrid automated machine integrating concurrent manufacturing processes, increasing the production volume of functional on-demand using high multi-material deposition rates)

Summary
The KRAKEN project aims at equipping SMEs and Large Industries with a disruptive hybrid all-in-one machine for the precise design, production, repair and quality control of large functional parts in aluminium grades, thermoset resins and a combination of both. The project is...\n\nThe KRAKEN project aims at equipping SMEs and Large Industries with a disruptive hybrid all-in-one machine for the precise design, production, repair and quality control of large functional parts in aluminium grades, thermoset resins and a combination of both.

The project is coordinated by Jose Antonio Dieste, Head of Mechatronics and Advanced Processes at AITIIP (Spain).

The KRAKEN consortium, coordinated by AITIIP, is integrated by 15 partners from 8 different countries. The project will last 36 months and has a budget of 5.9M?, 30% of which is allocated to SMEs. Other partners who participates are Acciona (Spain), Planit and Vero UK Software (United Kingdom), Leica Geosystems (Switzerland), CSEM (Switzerland), Pininfarina (Italy), Vision Business Consultants (Greece), Autonomous Systems (Romania), Centro Richerche FIAT (Italy), Cecimo (Belgium), Espace 2001 SA (Luxembourg), Alchemie Ltd (United Kingdom), Arasol (Spain), TWI (United Kingdom) and Teamnet World Professional Services (Romania).

The KRAKEN concept was born after the end (November 2015) of the successful MEGAROB FP7 Project, coordinated by AITIIP, in which parts were machined and finished in an area up to 20x6x3 meters, allowing to separate part size and accuracy concepts, paving the way for the production of large parts in a single machine. According to José Antonio Dieste ?the project will face three challenges: to develop new 3D industrial technologies, new subtraction technologies and finally to improve the quality and control of the manufacturing process. All of this in one of the bigger fabricating frames. KRAKEN will be able to work with parts of more than 20 meters?.\n\nThe first period of the project has gravitated around three different lines of work: hybrid manufacturing, software and positioning.

Our work on hybrid manufacturing has happened as part of WP2 ?Development of multimaterial additive manufacturing? (led by TWI) and WP3 ?Development of a hybrid manufacturing process? (led by AITIIP).
Additive metal technologies have been investigated by partner TWI, more specifically Arc Welding and LDM with wire and powder feed. In the Arc Welding case, modifications to both the power supply and the robot have taken place in order to achieve the desired deposition rates and qualities.
PU3720 is a two component styling (non-metallic) paste that has been specifically developed by partner ALCHEMIE to allow the building of large prototype models within a footprint of 20m x 8m x 6m. The material cures rapidly to allow a high deposition rate of 180 Kg per hour. In addition to the paste, a specific extrusion process has been developed by AITIIP. This system consists of a pumping mechanism for the paste plus a mechanism for balanced mixing, a deposition head and an automatic flow control. It is scalable and deposits material 200 times faster than a conventional printer. ARASOL has successfully arc-sprayed metal coatings for the previously mentioned PU3720 products, achieving bounding on direct printed resin and milled resin. In addition, further trials have shown bounding improvements when the metallisation is based on Zn.
Concerning the subtractive processes, the KRAKEN ?climb-up? methodology has been successfully demonstrated and LEICA?s laser tracker has been successfully integrated in AITIIP?s and CSEM?s facilities.

Concerning software, KRAKEN includes WP4 ?Integrated and automatic control system? (led by CSEM) and WP5 ?CAM and High level software? (led by TNWPS). At CSEM?s lab, a smaller scale, fixed-base robot and laser tracker have been implemented for developing the low-level software routines. CSEM and other partners of WP4 have designed the specifications for the control architecture of the fully automated machine, based around a modular design. This automated machine has closed-loop control and continuous quantitative monitoring capabilities and features the online adaptation of our manufacturing processes. The motion control and positioning of the robot head is based on absolute laser tracking. WP5 has focused on contributing to the objective of having a ?computer-aided? and intuitive user interaction.
As part of the activities of WP6. AITIIP is integrating the resin extrusion machine in Zaragoza. The Arc Wire machine will be ready by July 2018.\n\nBy the end of M18, KRAKEN is overall progressing well and its key objectives ? sustaining the expected impact ? remain strong, achievable and relevant. There is, at this point, no foreseeable deviation in M19-M36 from the expected impacts in the work programme that were listed in Annex A:
? 20% reduction in time and cost, with respect to the current additive and subtractive processes: KRAKEN will compare, once WP6 finishes, its cost effectiveness in relation to (1) the current combination of technologies that are presently used by the WP7 demo partners and (2) those new KRAKEN technologies able to implement parts with the same size and complexity. At this point WP5 has developed new CAM paradigms that should be able to effectively reduce the design time/cost, and also the reduced cure time of the KRAKEN paste plus the ability of the system to work with precision on different areas of the same part should help us achieve such important time and cost reduction as foreseen in Annex I to the GA.
? 15% increase in productivity for high-volume AM production, with respect to the current additive and subtractive processes: again, once WP6 is done and the full machine is ready, the consortium will compare productivity indicators on location with the WP7 demo partners. These will include the need or absence of post-treatment stations, real-time or on-demand production flexibility, reduction of floor space, and others.
? Reduction of inventory because of making of products on-demand, and more flexibility and robustness of the machines to adapt with customisation and changing market needs, which have been studied in WP2-3 and are currently being studied in WP5. During WP7, pilot partners will create benchmarks and LCAs of the current processes and will be able to compare these figures with those of KRAKEN ? a more flexible technology that is able to create products faster (high-rate deposition of both metallic and non-metallic materials as reported in D2.2 and D2.5, faster cure times as reported in D2.5) and with better quality control, as reported in D3.3.
? Contribution to standardisation and certification for new hybrid procedures, towards which VBC is continuing the acquisition and dissemination of standardisation-related information to all partners on ISO/TC261-WG2 on ISO/ASTM 52903 series of standards, its liaison to CEN/TC438, progress from the AM forum and standardization workshops from CEN/CENELEC and ISO/ASTM 52910.

An initial list of Key Exploitable Results ? connected to the Innovation Radar ? has been created in T8.3. The KRAKEN consortium has a detailed IPR policy agreed and signed by all partners in the project internal Consortium Agreement (now in its version 4). Additionally, the project has identified (as part of the Market Analysis, T8.1) the current main AM processes to which KRAKEN can be an alternative, and the key industries and markets at which KRAKEN aims. All these tools are expected to secure achievement of higher-level impact including the enhancement of the EU?s innovation capacity through new market opportunities, more competitiveness and new jobs while addressing environmental issues.
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Hybrid automated machine integrating concurrent manufacturing processes, increasing the production volume of functional on-demand using high multi-material deposition rates
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