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Is it possible to reduce the waste related to metal parts manufacturing to practically zero? Yes! And the answer lies in advanced 3D Printing.

General


Huge costs and the unpredictable defects in metal parts inherent to the additive manufacturing process are the two main reasons preventing the adoption of 3D printing of metal components.

With the aim of leading the incorporation of this technology into manufacturing industry the Integradde Project was conceived. It proposes a solution through the development and implementation of a global control system. The latter will allow to connect the entire manufacturing process, from design to production in a standardised way. The result will be a new, faster and zero defects manufacturing model.
 
The project will focus on 3D printing of metal parts of medium and large sizes, designed for the aeronautical, metal-mechanical, automotive and civil construction industries. 
 


The methodology that enables quality manufacturing with 3D printing proposed by the INTEGRADDE project.


The Benefits

The stakes are huge: in the aircraft industry, up to 90% of the materials end up being wasted. With additive manufacturing, waste will be reduced to practically zero. But this is not the only benefit the project will bring, it will also:

• Increase the reliability in additive manufacturing processes by 40% and manufacturing speeds by 25%

• Reduce time to market by 25% and improvement of the capacity to manufacture a good piece at first by 40%.

• Change the definition of the parameterization window of AM processes by 50%, allowing in turn improvements in product quality by 40%.

• Develop new certification schemes for metal parts printed in 3D

• Develop new standardization procedures not included in the current ISO / ASTM / CEN CENELEC Technical Groups


Applying the knowledge

The progress made will be tested by manufacturing firms that joined the INTEGRADDE initiative:

GKN Aerospace, to produce components of commercial aircraft engines;

ArcelorMittal, in the manufacture of large parts for the steel manufacturing process;

MX3D (a company that has created the first metal bridge manufactured by additive manufacturing) for civil construction solutions;

• Or firms such as Loiretech or Corda, to manufacture moulds and tools for the production of parts for the aeronautical and automotive sectors, respectively.

Besides, the members of this consortium will create a network to support companies who are contemplating incorporating additive manufacturing technology in their industrial processes. The network will help them evaluate the benefits and costs of 3D printing under real manufacturing conditions.


The innovation

To achieve the INTEGRADDE objectives, the members of the consortium will develop a strategy of continuous and integral control of the additive manufacturing processes, from the product design stage to its final verification.
In addition, they will:

• Analyse new design and process planning technologies, to help ensure that there are no manufacturing defects.

• Look for solutions that can be adapted to existing industrial equipment, but will also look for new manufacturing cells.

• Seek to combine different technologies (welding, machining, etc.) in order to achieve hybrid manufacturing processes.

• Apply data analytics and artificial intelligence, to support the design and manufacturing processes.

• Advise on the creation of new procedures for standardisation and certification of manufactured parts.


The INTEGRADDE Consortium

INTEGRADDE has a budget of around 17 million euros and is co-financed by the European Commission, through the Horizon 2020 program. The consortium, led by AIMEN, is made up of 26 partners from 11 countries: Germany, France, Slovenia, Spain, Greece, Italy, United Kingdom, Sweden, the Netherlands, Poland and Portugal.

The entities that make up the consortium are: AIMEN Technological Center (Spain), LimitState (United Kingdom), University of Sheffield (United Kingdom), ESI Software Germany GmbH (Germany), ATOS (Spain), Commission of Alternative Energies and Atomic Energy of France — CEA (France), Institut de Reserche Technologique Jules Verne (France), MX3D (Netherlands), Loiretech (France), Fundingbox Accelerator (Poland), Imperial College of Science, Technology and Medicine — University of London (United Kingdom), Bureau Veritas (France), IREPA Laser (France), Högskolan Väst (Sweden), New Infrared Technologies — NIT (Spain), GKN Aerospace (Sweden), Deutsches Institut für Normung — DIN (Germany), Arcelor-Mittal Innovation, Research and Investment (Spain), University of Coimbra (Portugal), Datapixel (Spain), Corda (Slovenia), DGH Robotics (Spain), Laboratory for Manufacturing Systems & Automation — LMS (Greece), Brunel University London (United Kingdom), Prima Industrie (Italy) and ESI Group (Germany).

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