fichas fabricacion avanzada - basque industry...lmd additive manufacturing complex part...

EKONOMIAREN GARAPENETA AZPIEGITURA SAILA

DEPARTAMENTO DE DESARROLLOECONîMICO E INFRAESTRUCTURAS

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ADDITIVEMANUFACTURING

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Laser laboratory for the analysis and development of solutions for additive manufacturing

The laser laboratory is an environment for research, development and industrial design of solutions for the Laser Metal Deposition process. With 2kW and 5kW sources, and different cladding heads, it can be used both for high precision applications (150mm spot) and for high productivity (up to 8kg / hour). It is prepared for a wide variety of materials (Inconel, Titanium, different compositions of steel, aluminum, etc.), and allows using gradients of composition to give the piece different mechanical properties (higher hardness, resistance to corrosion, thermal behavior...), in different areas of the piece.It also has a closed loop control system that allows

(unlike the other existing systems) to adapt the geometry of the material provided to the most appropriate size at each point, and its use for gradients of composition.

It includes the necessary equipment for the development of industrial LMD solutions, and the design of solutions for industrial implementation.

The system allows the additive manufacturing of complex geometries through its 5 axes of movement, and a work volume of 300x300x300mm3.

THE MOST OUTSTANDING EQUIPMENT AND COMPONENTS

• 5-axis machine tool for the development of Additive Manufacturing

• 2kW and 5kW fibre lasers.

• 2 laser cladding heads, for high productivity, and high precision (spot size between 0.15mm to 8mm).

• Closed loop control system, prepared to locally modify the objective geometry and adapt to the changes of composition desired

FIELDS OF APPLICATION

AM/3D Printing ProcessSupporting technologies and processesPost process



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SERVICES OFFERED BY THE ASSET

Development and process optimization: LMD

Together with the client, definition of the objectives of the process regarding the specifications of the part of interest (mechanical, thermal, anticorrosion properties...) both locally, superficially or in additive manufacturing. Definition of candidate materials, and process development. Definition of part solution.

Development of machines, technologies and productive means in Additive Manufacturing

From the piece requirements together with the customer, customized definition of machines for additive manufacturing. Design of the productive solution. Cost analysis, productivities.

Integration of Additive Manufacturing in current production processes. Hybridization of processes

Analysis of current structure and productivity requirements and target cost. Definition of line configuration or hybrid machine according to objective specifications.

Monitoring and control of the process

In the production chain. Integration of the solution for closed-loop control of the locally variable molten pool size, or customized adaptation based on the requirements of the target application.

ENTITY THAT MANAGES THE ASSET

IK4-IDEKO Contact Person:Jordi [email protected]



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3D Printing Filament Manufacturing Unit

Manufacturing unit and adaptation of thermoplastic compounds for 3D printing, formats: 1.75 mm and 2.85 mm diameter fi laments and pellets. The Unit has capacity for the elaboration of experimental batches between 200 grams and 20 Kg / day, of

rigid and elastomeric thermoplastic, reinforced composites, nanocomposites, biomaterials and high temperature thermoplastics (up to 380 ºC of fusion temperature).


• Micrompounder DSM Explore

Micrompounder DSM Explore of double conical screw, with mixing chamber volumen of 15 cm3, working temperature range between 21ºC and 400ºC, shear rate between 1 and 250 rpms.

• Pilot extrusion line

Pilot extrusion line with nozzles to make fi laments of 1.75 and 2.85 mm diameter and pellets, with a twin-screw extruder Leisbtriz Mico 27 GL, and a single-screw extruder Iqap Lap of 30 mm, Brabender gravimetric feeders, cooling system with water bath or air blow, and winding system.

• Single extruder

Pilot extrusion line with nozzles to make fi laments of 1.75 and 2.85 mm diameter and pellets, with a twin-screw extruder Leisbtriz Mico 27 GL, and a single-screw extruder Iqap Lap of 30 mm, Brabender gravimetric feeders, cooling system with water bath or air blow, and winding system.

• Granulator system

GALA LPU submerged granulator system with maximum granulation fl ow rate of 20Kg/h and 315 ºC of maximum service temperature of the perforated plate.

• Industrial fused fi lament printer 3NTR A2

Industrial fused fi lament printer 3NTR A2 with building heated chamber at 80 ºC degrees and dimensions of 620 x 355 x 500 mm, refrigerated extrusion head of 3 hotends (410ºC), and heated construction platform up to 135ºC.



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AM/3D Printing Process Supporting technologies and processes

Post process Design dor AM and Digital pre-procesing

AM Digital Chain Materials for 3D/AM

AM process validation


Development of new 3D printing polymeric materials

Customized formulation of pellets and filaments of 3D printing of 1.75 mm and 2.85 mm of diameter. Adaptation of thermoplastic compounds in 3D printing filaments. Definition of product and process technical sheets. Determination of the qualitative and quantitative composition of 3D printing materials.

Design and product development through FFF / FDM technology

Design and manufacturing models, parts, inserts and tools through 3D printing with FDM technology. Development and evaluation of printed molds in processes of thermoplastics and composites transformation.

Optimization of process parameters

Optimum adjustment of the process parameters, and chemical, morphological, physical, microstructural, mechanical and fire behavior according to standards (ISO, UNE, ASTM, DIN, BS). Application of post-treatments and elaboration of processes guides and 3D printing protocols for materials and final parts.

Sustainability and recyclability evaluation

Evaluation of the additive manufacturing process sustainability through Life Cycle Analysis (LCA), environmental and economic methodologies. Development and implementation of recycling systems.

Evaluation of emissions toxicity

Study of in vitro toxicity and ex vivo models (digestive tract, lung, heart, brain ...) of nanoparticle emissions (collected in situ) in 3D printing processes. Preparation of protocols.


GAIKER-IK4 Contact Person:José Luis Gómez [email protected]



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Laser Metal Deposition (LMD) cell for laser cladding AKTINOS 500

5 axis LMD cell with 600x400x400mm workspace and two rotary axis A± 110°/C360°.

- 1kW fi ber laser with 2 beam guiding fi bers of 100 and 600 microns

- Fagor 8070C CNC with Ethernet connection for remote program loading and process monitoring.

- LMD process monitoring system integrated: Temperature close loop control with pyrometer, laser track height online measurement, meltpool monitoring with high-speed camera.

- Specifi c API integrated in NX for complex trajectory programming in 5 axis.


• Aktinos 500 LMD system


AM/3D Printing Process Design dor AM and Digital pre-procesing

Post process Materials for 3D/AM



Adaptation of laser additive systems in situ

Laser cladding nozzle design, advice on laser additive set-up confi guration, design and equipment specifi cations

LMD Additive Manufacturing (AM)

Complex part manufacturing by LMD in diff erent materials



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UPV/EHU Contact Person:Aitzol Lamikiz [email protected]

Part coating by laser cladding

Improvement of tribological properties on complex parts by laser cladding (friction, wearing, thermal…) of ceramic materials


LMD process comparison with other AM processes: Mechanical properties characterization, metallurgical structure, process capabilities, requirements, etc.

Part repair by LMD


Advanced Training in LMD

Customized training in LMD technology, applications, equipment, programming, strategies, powder handling and recycling.



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Renishaw AM400 SLM additive manufacturing system

SLM additive manufacturing system (metal 3D printing) with maximum working volume of 250x250x300mm

http://www.renishaw.com/en/am-400--35456

- 400W fi ber laser with 2D scan-head and surface speed up to 7000mm/s

- Ar inert chamber with initial vacuum.

- Magics and QuantAM softwares

- Part heat treatmnent in Ar controlled atmosphere.

- Layer height of 30 or 60 microns


• Renishaw AM400 SLM additive manufacturing system






SLM additive manufacturing

Part manufacturing by SLM in diff erent geometries and alloys

Benchmarking of AM technologies

SLM process comparison with other AM processes: Mechanical properties characterization, metallurgical structure, process capabilities, requirements, etc.



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UPV/EHU Contact Person:Eneko Ukar [email protected]

Study of mechanical integrity in parts manufactured by SLM

Evaluation of mechanical properties and metallurgical structure in components build up in SLM

Analysis of SLM manufacturing strategies

Process parameter and optimal strategy development

Support structure configuration analysis

Study of support structure geometry and placement

Advanced training in SLM

Customized training in SLM technology, applications, equipment, programming, strategies, powder handling and recycling.



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Laser Metal Deposition (LMD) cell for laser cladding Trumpf Trucell3000

5 axis LMD cell with 300x300x300mm workspace and two rotary axis A± 135°/C360°.

- TruDisk 3kW disk laser and dual guiding fi ber with core of 100 and 400 microns ring.

- Siemens CNC with TruTOPS software for5Ax path programming.

- Ethernet connection for remote program loading and process monitoring.

- Integrated Process monitoring system: Temperature measurement with pyrometer, and mel-tpool monitoring with coaxial camera.

- Complex trajectory programming in 5Ax with API integrated in NX.


• Laser Metal Deposition (LMD) cell for laser cladding and part repair. Trucell 3000






LMD Additive manufacturing

Complex part manufacturing by LMD in diff erent materials

AM Technology benchmarking

LMD process comparison with other AM processes: Mechanical properties characterization, metallurgical structure, process capabilities, requirements, etc.



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Laser cladding nozzle design, advice on laser additive set-up configuration, design and equipment specifications

Part coating by laser cladding


Part repair by LMD

LMD technology evaluation for very high-added value part repair

Advanced Training in LMD

Customized training in LMD technology, applications, equipment, programming, strategies, powder handling and recycling.



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Stratasys Dimension SST1200es and SST768 FDM additive manufacturing system

FDM additive manufacturing system for printing parts up to 254x254x305mm(SST1200es) in ABS+ or 203x203x305mm (SST768) in ABS.

- 2 head to print part material and support material in each layer.

- Complete software solution for CAD geometry import, placement, slicing and later machine programming.

- Diff erent materials: ABS, ABS+… in diff erent materials (check material availability).

- Dissolvable support material: possible to print inserts that are lately dissolved.

- Prototype or functional part manufacturing in industrial polymers.


• Additive Manufacturing, 3D printing, ABS, ABS plus, FDM, prototype, Stratasys Dimension, composites, design for additive manufacturing


Part manufacturing by FDM

Part manufacturing by Fused Deposition Modeling (FDM), including prototypes, test parts, etc.

AM Technology benchmarking

FDM process comparison with other AM processes: Mechanical properties characterization, Polymer structure, process capabilities, requirements, etc.

Part design optimization

Application of design optimization criteria (topological, structural, thermal,…) on target components



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Analysis of mechanical properties

Characterization of mechanical properties in prototypes/functional parts build up by FDM

Advanced training in FDM

Customized training in FDM technology, applications, equipment, programming, strategies.



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Non-contact 3D ATOS GOM scanner for digitalization

Hardware and Software global solution for inverse engineering and metrology inspection:

- 3D digitalization system ATOS GOM 5Mp based on structured blue light.

- HANDYSCAN 3D digitalization system from CREAFORM.

- GO!SCAN 3D digitalization system from CREAFORM.- FDM Dimension ELITE rapid prototyping system

from STRATASYS.- ZPRINTER 450 prototyping system from 3D

SYSTEMS.- Geomagic Design X software for inverse engineering.- Geomagic Control X software for inspection.- GOM Inspect software for inspection.


• Contactless 3D ATOS GOM scanner for digitalization and inverse engineering, inspection or 3D metrology


Precision metrology digitalization

3D digitalization by structured white light scanner from ATOS with resolution up to 0.01mm

Digitalization with handheld scanner system

3D digitalization with portable laser r and structured white light scanners (resolution between 0.05 and 0.5mm)



AM process validation Materials for 3D/AM



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UPV/EHU Contact Person:Rikardo Minguez Gabiñ[email protected]

Photogrammetry

Taylored photogrammetry turnkey installation (3D digitalization by 2D photography)

Rapid Prototyping

Rapid prototyping in different color ABS plus (0.17mm layer thickness) and reinforced ceramic powder (0.1mm layer thickness)

Advanced training in metrological inspection

Customized training in 3D contactless metrology and inspection measurements

Inverse engineering advanced training

Customized training in 3D digitalization and point cloud conversion to CAD format with geometrical constraints



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WAAM Machine for metal components manufacture

WAAM Machine for metal components manufacture

Features:

- Own CNC specific for additive manufacturing- Max. piece size: 1400x900x500mm aprox.- Max. piece weight: 300Kg- X-Y-Z axis feed: 15-15-2 m/min- Possibility to deposit on both sides

- Capacity of plasma, CMT® and TopTIG® generators integration- Fairing with inert gas atmosphere: designed to work with highly oxidisable parts- Interface that facilitates the machine use- WAAM CAD/CAM system- In-process monitoring system- Traceability system. Part manufacturing report.


• Addilan Machinne v1.0

• Plasma Tetrix 400 confort

• Equipo MIG Kemparc Pulse 450

• Termographic camera

• Laser scanner with light compensation



Post process AM Digital Chain

AM process validation Supporting technologies and processes



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Manufacturing of several geometries using WAAM

Parameter optimization, tool path and simulation programming, whole 3D part or specifi c geometries manufacturing and part measurements.

Feasibility analysis of part manufacture using this technology

Part manufacturing optimization using additive manufacturing. Development of trajectories and manufacture of demonstrator.

Model development for additive manufacturing

Development of models that relate the characteristics of the deposited material (geometry) with the monitored process parameters for the development of control rules

Piece design support

Support the redesign of the parts that will be manufactured by WAAM (plasma and MIG)

Validation and advice of new products for additive manufacturing

Integration, evaluation and advice in the improvement of new equipment, sensors and accessories for additive manufacturing by WAAM (3D measurement scanners, fi lling torches, postprocessors, simulation tools, etc.).

Training

Technical training in WAAM process (theoretical-practical, WAAM, MIG).


FUNDACIÓN TECNALIA RESEARCH& INNOVATION Contact Person:Alfredo [email protected]



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RX/computer tomography cell GE model X-CUBE compact 225

Digital radiography and 3D computerized tomography system from GE model X-CUBE compact 225.

- Max. sample size 600 x 900 mm.

- 195 kV version.

- Control and 3D part generation software. Computerized software.

- Ethernet connection for data loading.


• Digital computerized radiography and 3D tomography cell from GE model X-CUBE compact 225






Analysis and inspection of parts build by SLM

SLM part inspection to detect internal cavities, part density, retained powder, internal cavity measurement.

Advanced training on RX inspection

Customized training in RX inspection technology



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Analysis and inspection of parts build by LMD/WAAM

Bonding analysis between added and base material. Crack detection, detection of defects because of lack of joining, detection of areas without material



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5 axis hybrid multiprocess center (machining + LMD): ZVH Add+Process

High productivity 5 axis ZVH 45/1600 Add+Process Multiprocess machining center from Ibarmia manufacturer, with moving column and tilting head, for turning in horizontal (ø=750mm) and vertical (ø=1100mm) plates, machining in 5 axis with A+B and B+C and additive manufacturing by LMD-powder technolgy. The X/Y/Z and B axis courses

are of 1600/800/900 and +105º (+45º with LMD head) respectively.

Toolpath programming and simulation in the commercial Powermill® CAM software. Measuring of manufactured part by structured light technology.


• Machining center ZVH Multiprocess 45/1600 Add+Process from Ibarmia manufacturer

• Laser Source FL030 MM(FFC/FFS) 3kW fiber laser from Rofin manufacturer with a refrigeration system from Lotec manufacturer

• 4-stream YC52 LMD head from Precitec manufacturer

• Structured Light technology cameras for parts measurement

• Thermographic camera OPTRIS (Temperature of 1000-2000ºC)


AM/3D Printing Process Supporting technologies and processes




Recovery and repairing of high value-added parts

Defect detection by structured light technology, restructuring of the part by machining, laser cladding and finishing. Capability of automating the entire repairing/recovery process



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Coating by LMD (laser Cladding)

Optimization of process parameters, material selection for improvement of properties (hardness, wear resistance, etc.) of areas subjected to high wear.

Feature addition or 3D part manufacturing by LMD and fi nishing

Parameters optimization, toolpath programming and simulation, 3D part manufacturing or feature addition, fi nishing by machining and part measuring.

Testing and validation of new powder materials

Powder characterization, evaluation of the processability of new powders by means of the LMD technology, characterization of metallurgical/mechanical properties that are obtained when processing by LMD, search of optimum LMD parameters for processing the powder.

Training

Practical training in the LMD process and machine management.

Support in the design of parts

To give support in the redesign of the parts that are going to be manufactured by LMD

Feasibility analysis of manufacturing of parts by hybrid manufacturing (LMD+machining)

Optimization of part manufacturing through combination of machining and LMD processes. Development of toolpaths and manufacturing of a demonstrator part.

Development of databases and geometric models for LMD

Development of databases and models that relate the characteristics of the added material (geometry) with the monitored process parameters.

Advice during development and validation of new products for additive manufacturing

Integration, evaluation and advice in the improvement of new equipment, sensors and accessories for additive manufacturing by LMD (3D measurement scanners, LMD heads, postprocessors, simulation tools, etc.).



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WAAM additive manufacturing robotic cell

Adapted robotic cell for the WAAM additive manufacturing, by plasma, wire and MIG that has integrated sensors to ensure the correct deposition

of the material, adapting the deposition parameters according to the previously deposited material and the geometrical characteristics of the final part


• Plasma Tetrix 400 confort

• PMW – 350 2 torch

• MIG Kemparc Pulse 450 equipment

• Vision camera for welding processes

• Laser scanner with light compensation






Manufacturing of several geometries using WAAM (plasma and MIG)

Parameter optimization, tool path and simulation programming, whole 3D part or specific geometries manufacturing and part measurements.



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Feasibility analysis of part manufacture using this technology

Part manufacturing optimization using additive manufacturing. Development of trajectories and manufacture of demonstrator.

Model development for additive manufacturing

Development of models that relate the characteristics of the deposited material (geometry) with the monitored process parameters for the development of control rules.

Piece design support

Support the redesign of the parts that will be manufactured by WAAM (plasma and MIG)

Validation and advice of new products for additive manufacturing

Integration, evaluation and advice in the improvement of new equipment, sensors and accessories for additive manufacturing by WAAM (3D measurement scanners, fi lling torches, postprocessors, simulation tools, etc.).

Training

Technical training in WAAM process (theoretical-practical, WAAM, MIG).



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Parts development center using Binder Jetting technology

Powder bed process. The powder is deposited in a container and the head dispenses a binder that agglomerates the powder in the selected areas. Subsequently, another layer of powder is dosed and the process is repeated until the piece is finished. There is no heat source during the printing process. The binder is used to create a “green” the printed part.

The green part is sintered, infiltrated or used as-printed.

Different forms of products: dense parts, porous parts and multiple materials.

Pieces with very good surface finishing: Roughness Ra = 6 microns (in the as sintered parts


• Innovent ExOne Binder Jetting equipment

• Spry Dryer YAMATO: powder granulation.

• Sintering furnaces with controlled atmosphere up to 1400C

• Sintering furnaces with high vacuum up to 2000C

• Curing ovens



Post process Materials for 3D/ AM




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Manufacturing of components by Binder Jetting

Optimization of parameters, simulation, design of parts, sintering and fi nal fi nishing

Feasibility study of the manufacturing of the parts by Binder Jetting

Evaluation of new applications of components obtained by BJ. Study on the technical-economic feasibility for the manufacturing of components using the BJ

Manufacturing of models and prototypes through Binder Jetting

Manufacturing of new models or prototypes of parts with new designs

Development of new composite materials (metal-ceramic)

Development of materials with customized properties according to the needs that allow replacing the current ones. Mainly development of ceramic metal composite materials that allow to design the properties required in each application.

Training

Technical training in the Binder Jetting process





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Center for Development of Additive Technologies for Plastics and Composites

The Centre has the capability to develop or reformulate new binders and thermoplastic resins a) suitable for processing by means of additive technologies such as FDM (fi lament or direct extrusion) and Laser sintering or b) to meet new requirements (mechanical, fi re resistance,

electrical, etc.).), new additive processes for the pre-forming of composites with continuous fi ber, post-processes to improve surface and mechanical properties, design of moulds and tools, integrate electrical functions in non-metallic components and develop new equipment and control software.


• Materials development Unit: Extruders for extrusion and co-extrusion and injection, additive dispersion equipment (Calender, mill, Dispermart, baths and ultrasonic tips)

• Additive Manufacturing Unit: Stratasys uPrint SE 3D Printer, TUMAKER Printer, ZORTRAX M200 Printer, EOS - SLS Printer

• TFP (Tailored Fiber Placement) equipment for the manufacture of preforms by means of TFP or stiching of carbon fi bers, glass, aramid, etc.

• Electronic printing Unit: printing equipment for conductive inks and pastes (injet, screenprinting, laser sintering)


Materials development

Reformulation and development of new materials to obtain better or new features with additive processes



Post process Materials for 3D/ AM

Supporting technologies and processes



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Product development

Design, topological optimization and validation of components and tools. Electrical/electronic function integration

Process development

Development of Additive Technologies for preforms manufacturing

Post-process development

Surface and resin infi ltration treatments to improve the performance of parts or tools



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HVOAF: High Velocity thermal spray combustion technology with controlled temperature

HVO/AF stands for High Velocity Oxy- Air Fuel spraying. HVOAF torches are operated with natural gas and air-oxygen mixtures. These torches are able to operate within the supersonic regime using a broad range of fuel/oxidant ratios, thus allowing their operation with either extremely low

or “conventional” flame temperatures. The gun configuration can be easily tailored for processing materials with very different physical natures with superior deposit qualities, including almost all industrially relevant metal base and cermet materials.


• Thermal spray torch for light metal alloys (Al, Cu, Zn- basis)

• Thermal spray torch for cermet type materials, e.g. WCCoCr, WC-CrC-Ni, Cr3C2-NiCr,

• Accuraspray-G3C On-line monitoring system for HVOF torches

• Thermal spray booth with capacity to handle flat components from up to 1.5 x 1.8 m OR cylindrical components in size of up to Ø:0.3 m x 1.5 m


Development of new coatings

Development of new coating from experimental metallic and/or cermet type powders.

Development of new applications

Development of coating procedures for new demanding applications starting from either experimental and/or commercially available feedstock powders.



Post process Supporting technologies and processes



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Fabrication of pre-serie

Manufacture of pre-series and proof-of-concept validation under industrially relevant conditions.



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Connectivity and Technical Interoperability for the IIoT field

This logic active, of transversal application, pretends to provide to the machines/installations of Additive Manufacturing, the level of CONNECTIVITY demanded in the Industry 4.0 field, covering aspects of data transport (physical media and communication protocols), but also TECHNICAL INTEROPERABILITY – via APIs (Application Programming Interfaces), between the different functional modules (sensorization, local data processing, data ingestion, stream processing, batch processing, data storage, analytics, data presentation, …) that make up the Industry 4.0-oriented platforms.

Technical interoperability deals with purely technical aspects of interoperability such as transmission protocols and data exchange formats between the functional modules.

This active propose a Reference Architecture structured in three layers (Machine, Edge and

Cloud), specially oriented to guarantee the response time (latency) and the level of security/privacy required by the services provided in each of the above layers.

The elasticity of the architecture facilitates its application in use cases of Additive Manufacturing such as: monitoring and remote control, condition-based maintenance, automation of decision-making at operational level, quality control online, etc.

This architecture refers to: a) physical means of communication: Ethernet, xDSL, Wifi, Bluetooth/BLE, ZigBee, GPRS, 3G/4G, SIGFOX, LORA, NB-IoT, … , b) Communication Protocols: OPC-UA, Modbus, HTTPS, Web Services, REST, CoAP, MQTT, …, y c) APIs to integrate functional modules: NIFI, KURA, VAGRANT, ANSIBLE, APACHE SPARK, APACHE CASSANDRA, APACHE ZEPPELIN, ...


• Machine level connectivity

Wired Communication (UART, GPIO, SPI, I2C, CAN, USB,...) and wireless (IR, Bluetooth, Wifi, Zigbee, LPWAN,...) with industrial devices (CNCs, PLCs, transducers). Real-time local data processing capability. It can communicate directly with the upper levels (Edge and Cloud) using standard protocols in the IIoT field. Configuration, calibration, filtering/data adequacy and security-related decision-making services are typical at this level.



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• Edge level connectivity

Infrastructure aimed at providing data ingestion and stream processing services, with a response time of the order of the tenth of a second. Communicates with the lower level (Machine) and above (Cloud) using standard IIoT protocols. This level implements Internet technologies in a near-machine environ-ment, on a platform (hardware/software) dimensioned according to the privacy/security and latency requirements demanded by the node-resident services. NIFI and KURA are two of the relevant ele-ments of the EDGE node. This node plays three basic tasks: a) Provide the degree of privacy/security and latency demanded at this level, b) implement services that require aggregated data from different machines, and c) serve as a gateway between the machine and the services available in the cloud. Services related to the dynamic reconfiguration of the production line, integration of 'plug-and-play' machines, 'quasi-real' time monitoring of the critical process variables, and intelligent maintenance based on conditions, are Just some of the typical services on this level.

• Cloud level connectivity

Infrastructure aimed at providing data ingestion, data storage, data analytics and data/information pre-sentation, with a response time of the order of the second. It can communicate directly with the lower levels (Edge and Machine) using standard IIoT protocols. This infrastructure uses virtual machines and clusters installed on distributed servers to ensure the levels of availability demanded by the services. The enormous processing capacity available at this level allows to face self-learning services oriented to the modeling of the behavior of the machine, quality control on-line, unit traceability, automatic ope-rative decision making, man-machine agile interfaces, etc.


Education, training, experimentation

Education, training and experimentation around the potential of the Reference Architecture in order to facilitate the process of creating infrastructure/platforms in the field of Additive Manufacturing. As-pects related to the implementation of the most relevant communication protocols (OPC-UA, REST, MQTT and Coap), and with the integration through APIs (technical interoperability) of the most popular functional modules: Data transport ( Nifi), Edge Computing (Kura), ingest and Data Control (KAPUA), re-al-time processing (spark steaming, Storm), batch processing (HDFS, Elastic, Influxdb, Spark Analytics), serving Layer (Apache Zepelin, Traefik), cluster Management (Mesos, Jenkins , Docker, Sonarcube, git), virtual machines (VirtualBox), cloud providers (AWS, Azure) will be considered.

Technical Interoperability and Connectivity demonstrators

Presentation of Machine, Edge and Cloud level connectivity demonstrators based on the most widely used IIoT communication protocols, and the technical interoperability APIs of the most relevant functio-nal modules in the field of Industry 4.0.

Techinal connectivity

Technology Transfer (collaboration with the client) in the field of IIoT connectivity directed towards the implementation of infrastructures/platforms oriented to Additive Manufacturing. It focuses on Machi-ne-Edge-Cloud connectivity aspects.

IIoT Technical Interoperability

Technology transfer in Industry 4.0 scenarios through the joint development of monitoring, control and predictive maintenance projects in the context of Additive Manufacturing. It complements the Con-nectivity service with Technical Interoperability aspects -via APIs, in order to integrate the functional modules (software components) required by services.



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IK4-IKERLAN Contact Person:Lorenzo Manero Pelá[email protected]



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Robotic cell for the construction of large components by concentric wire deposition

Large 3D metal printing by laser cladding in wire: 6 degree robotic cell (gdl) with a turntable and additional tilt (2 gdl) for the construction of large components (up to approximately 1m3 in volume) at high deposition rates of up to 6kg/h. Possibility of depositing in external structures with a material cost similar to the arch (WAAM) with free path generation. Possibility of depositing and investigating the 3D geometries generated in any thread material. In addition to this asset,

Tekniker includes structural calculation capabilities (topological optimization), material analysis (optical and electronic microscopy), 5-axis machining operations, thermal treatments, surface coatings and the generation of deposition paths for robots suitable for concentric powder and wire technology. Additionally, specimens and components can be manufactured in oxygen reactive materials due to the bag system that generates an atmosphere in inert gas due to overpressure.


• Fibre laser 4kW

• Robot and table with 8 degrees of freedom for components up to 1m3. CAM for robot path generation

• Wire deposition head

• Closed loop geometric control system

• Bag system for atmosphere control







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Demonstration / Approach

Demonstrator of large component construction by concentric wire deposition in advanced/new materials and oxygen reactive materials

Construction of large 3D geometries

Testing of large three-dimensional components manufacturing (>300mm) at high deposition rates on various air-reacting materials using wire-based LMD technology

Training

Practical training in the whole process (design, calculation, material analysis, process, coatings, NDT) of construction of large components by concentric wire deposition.

Development of wire based LMD technology, equipment and machinery

Development, testing and validation of special equipment and technology (heads, optics) for deposition in special environments or geometries. Adaptation of machinery for hybridization using wire-based technology.

Process development

Development of deposition parameters and strategies for new metal alloys. Testing (metallography, fatigue, mechanical characterization, etc.).

Control system development

Development of closed loop control systems for geometric and thermal control of deposited material.


FUNDACIÓN TEKNIKER Contact Person:Joseba [email protected]

Logotipo original



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Machine - 3D Printer for Concentric Wire Deposition Construction of Large Components in Advanced Materials and Oxygen Reactive materials (Ti)

Large 3D metal wire printing for oxygen reactive materials with oxygen: Cartesian machine of 3 degrees of freedom (gdl) with the possibility of adding a turntable and additional tilt (2 gdl) for the construction of high value-added components (e. g. titanium) of large size (up to approximately 1.4m3 in volume) at high deposition rates of up to 6kg/h in controlled atmosphere. Possibility of depositing in materials that are reactive with oxygen both in powder and concentric yarn with freedom of

trajectory generation. Possibility of depositing and investigating the 3D geometries generated in any material, both in yarn and powder, even when these are reactive with oxygen. Chamber technology based on vacuum and controlled atmosphere in order to make technology cleaner and more efficient while optimizing the internal quality of the material minimizing the appearance of pores and cracks induced by the gas.


• Diode fibre laser 10kW and fibre laser 4kW

• Component size 1.9x0.9x0.8m3

• Wire or powder concentric deposition heads


• Thermal monitoring system







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Demonstrator of large component construction by concentric wire deposition in advanced materials and oxygen reactive materials (Ti).


Testing of large three-dimensional components manufacturing(>300mm) at high deposition rates on various air-reacting materials using wire-based LMD Technology.

3D construction of oxygen reactive components

Optimisation of the construction process of reactive components to Oxygen and high added value alloys in a controlled atmosphere chamber and even vacuum.

Training

Practical training in the whole process (design, calculation, material analysis, process, coatings, NDT) of construction of large components by concentric wire deposition in advanced materials and reactive with oxygen (Ti).

Development of technology, equipment and machinery

Development of machinery associated with the laser cladding process or LMD in robotic and Cartesian format. Machinery for conventional and reactive materials with oxygen.



Logotipo original



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Robotic cell for large component construction by powder deposition

Large 3D metal printing with powdered laser cladding: Robotic cell with 6 degrees of freedom (gdl) with an additional turning table (1 gdl) for the construction of large components (up to approximately 1m3 in volume) at high deposition rates of up to 6kg/h. Possibility of depositing in external and even internal structures (by means of specific heads) both in a material and in a mixture of materials generating mixtures of materials of variable concentration (‘ graded materials’). This asset allows us to study different

materials, geometries and use cases that can be manufactured by means of laser cladding. The implementation of a closed loop process control system is also offered within the asset in order to optimize the process and detect premature failures in the manufacturing process. Additionally, new nozzle designs and deposition heads can be tested in this cell, as well as the development of deposition paths (CAM) to reduce distortions and geometric failures in the manufactured components.


• Diode laser 10 kW and Nd:YAG 2.2kW

• Robot and table with 7 degrees of freedom for components up to 1m3. CAM for robot path generation.

• 2 powder deposition heads, internal and external surfaces


• PLC-regulated double powder feed system with % mix regulation design by PLC







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Demonstrator of large component construction by powder deposition by LMD


Testing of large three-dimensional components manufacturing(>300mm) at high deposition rates on various materials or graded materials

Manufacture of 3D geometries in new materials.

Evaluate the suitability of new materials to be processed by LMD

Development of coating technologies and component repair.

Test the implementation of special and novel coatings as well as the development of component repair methodology, its inspection and testing for various sectors (aeronautical, marine, energy, etc.).

Training

Practical training in the whole process (design, design, calculation, material analysis, process, coatings, NDT) of large component construction by powder deposition.

Development of equipment and technology LMD powder.

Development, testing and validation of equipment and special technology (nozzles, heads, optics) for the deposition in environments or special geometries. Adaptation of machinery for the inclusion of powder deposition heads by DML.

Process development

Development of deposition parameters and strategies for new metal alloys. Testing (metallography, fatigue, mechanical characterization, etc.)

Control system development

Development of closed loop control systems for geometric and thermal control of deposited material.



Logotipo original



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Atomizer

The asset is a Hermiga 3 VI atomizer from PSI. It produces powder from the breakage of a melt stream through the action of high pressure water or gas (close couple die). The melt is obtained by induction melting under vacuum or controlled atmosphere (VIM system). The raw material to be melted can be pure metals, a combination of pure metal and precursors or pre-alloyed metals. The asset works with a crucible of approximately 1 l and subsequently around 3 kg of steel powder can be produced by heat. An upgrade to reach 10 kg/heat is ongoing. The temperature of the melt can reach 1850 °C and the atomization parameters can be set

modifying the flow of gas/water, melt chamber overpressure, over-heating, nozzle design, die design, kinetic energy of the gas …The atomizer was a commercial version but it has been upgraded with in-house development looking for: control of the Particle Size Distribution (PSD) in search of finer or coarser powder and finer or wider distribution as a function of the application. The shape of the powder particles has been studied and their defects minimized (antisatellite system, control of the internal porosity, segregations, oxygen content, and impurities).


• Atomizer PSI Hermiga 75/3 VI

• High pressure water pump/nozzles (1000 bar)

• New die looking for higher gas to melt ratio

• Anti-satellite system

• Hybrid gas/water atomization



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Production of metallic powder

Production of powder according to the standards of the different AM technologies based in metallic powder: powder bed, flown powder

Non-standard powder, new compositions

The possibility of producing powder designed for particular applications out of the standard compositions is offered.


CEIT-IK4 Contact Person:Jose Manuel Martín Garcí[email protected]



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Hot Isostatic Press (HIP)

The asset is a HIP unit model ASEA QIH-6 able to reach pressures as high as 2000 bars and temperatures up to 2000 °C with a graphite heating element and 1450 °C with a Mo heating element (both available). The working volume is a cylinder with 110 mm in diameter and 240 mm high. Workload can reach 30 kg and the standard atmosphere is Ar although the graphite-heating element also accepts nitrogen. The working area is in the interior of a wire reinforced pre-stressed

vessel. The vessel has been designed according to Fracture Mechanics criteria to guarantee leak before cracking. The axial stresses are supported by a wire reinforced frame. The asset is very flexible in the design of the temperature and pressure cycles. HIP is mainly use for healing defects (pores, cracks, segregations, directionality in properties) but also as heat treatment simplifying the production sequence.


• ASEA QIH6 HIP unit

• Connection to the internal network


Process parameters optimization

Determination of the optimum HIP parameters in order to improve the mechanical behaviour. This service includes tests at different Pressures, temperatures, times, chemical composition, mechanical and microstructural characterization.

HIP to improve the properties of components produced by AM

HIP is present in the AM value chain as a post-process (as a next step to the 3D printing). The main function is the improvement of the mechanical behavior of the parts healing defects (pores, cracks do not connected with the surface of the parts, segregation, columnar structure …). The improvement in properties are also associated to a decrease in the deviation obtained as well the residual stresses. It also allows (depending of the cooling capacity) the reduction of the process steps simplifying heat treatments.



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CEIT-IK4 Contact Person:Iñigo Iturriza [email protected]

Production of prototypes and demonstrators

Post-processing in AM: HIPping of AM prototypes and demonstrators

Technical feasibility studies.

Validate the technical and economic feasibility of the production of parts by AM+HIP



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Multifunction laser cell for additive manufacturing and post-processing

The multifunction laser cell is designed for two applications:

• Additive manufacturing of metallic part using Laser Metal Deposition (LMD)

• Laser post-processing of parts manufactured by any method (additive, subtractive, …)

Additive Manufacturing by LMD

This asset has a 4 kW continuous fiber laser, a state of art cladding head (acquired in December 2016) and a closed-loop system of the melt pool. The maximum part size is 1.200 mm diameter x 700 mm height. These dimensions are achieved by a 6 DoF robot and a positioner with two rotations which allows for complex part geometries.

The laser spot can be adjusted continuously between 0.2 and 10 mm, which allows for high precision or high productivity applications.

The raw material is metallic powder which is supplied with a powder feeder that has two hoppers which allows for gradient compositions.

The available materials include inconel, titanium, aluminium, different steels, etc.

The asset has all the necessary equipment to develop industrial solutions for LMD.

Additionally, Ceit-IK4 has equipment and knowledge, related to this asset, for: design for AM, topology optimization, material analysis (optical and electronic microscopes, mechanical characterization), generation of deposition trajectories for robots (specific CAM for robots for AM)

Laser post-processing

Using a 3D laser scanner and the same 4 kW laser source, it is possible to perform heat treatments and surface finishing (cleaning and polishing). The working volume for the scanner can be changed between 300 x 300 x 20 mm and 1200 x 1200 x 600 mm. This volume can be extended if the scanner is mounted in the Kuka robot. The process temperature is monitorize with a two color autocalibrated pirometer.



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• KUKA robot KR30 HA and KUKA DKP400 positioner (2 rotary axis)

• 4 kW IPG fiber laser with 4 outputs

• Additive Manufacturing LMD Head by Fraunhofer with a motorized collimator

• 3D Laser Scanner (Raylase AXIALSCAN-30)

• Commercial closed-loop control system for the melt pool





Materials for 3D/AM


Design/redesign of parts for LMD

Design of new parts or redesign of existing parts for LMD using methods as topology optimization

Process parameter optimization

* Additive manufacturing: optimal tuning of the parameters that control the LMD process. This includes test in the LMD cell, microestructural analysis, composition analysis, mechanical properties, etc. * Post-processing for AM: optimal tuning of the parameters that control de heat treatment or laser surface finishing

Powder optimization for LMD

Optimal tuning of the powder characteristics. Powder size distribution, humidity, defect types, etc. are key factors. Our 30 year experience in powder metallurgy and 10 years atomizing powders allows as to tailor the powder for each case.

Demonstrators and prototypes

Through demonstrators and prototypes we can explore AM in terms of design, properties, new functionalities, manufacturing, …

Training

Theoretical and practical training about laser post-processing and all aspects of AM( design, topology optimization, materials analysis, process optimization, CAM for AM, handling and management of metaling powders, …)



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CEIT-IK4 Contact Person:Mikel Gomez Aranzadi [email protected]

New technologies evaluation

We can evaluate new technologies within our multifunction laser cell for AM, heat treatments and surface finishing. For example, test a new sensor, a new equipment integrated in our cell, etc.

Viability studies

Validate the technical and economic viability of producing part by LMD and the associated technologies.



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Cell. Competence Center of Additive Manufacturing based on High Deposition Rate by direct deposition of powder and wire (LMD and WAAM)

Pilot cell for the application and comprehensive development of metallic additive manufacturing in Directed Energy Deposition technology.

Equipment, resources, software (CAD-CAM), knowledge related to additive manufacturing (LMD and WAAM) are made available for the companies. This also includes the study of the process industrialization and the integration of those processes in the production chain (combination of the total flow of manufacturing from the powder/wire to additive manufacturing process, heat treatments, machining and surface treatments).

It is available:

- 4 robotized cells

- A gantry (7 x 3 metres)

- 2 facilities of 3 axes (possible to include a fourth rotation axis)

LMD-powder. These facilities are able to combine with three optics and nozzles for LMD (one of them is capable of controlling the deposition width in real time). It is possible to simultaneously feed with two different materials.

WAAM-wire_with PAW, TIG and CMT technologies (Fronius) with different technologies of deposition

path control (equipment continuously updated 2017).

It is provided the possibility of working with reactive materials like titanium (in controlled atmosphere) and with control systems of local atmosphere (with local protection system, in development by Addispace project).

This infrastructure currently presents a series of sensors to the capture of process data (developed in COMBILASER project 2015-2017) and it is possible to establish the required connectivity for ICT platforms. Finally, it is worth noting, the development of a CNC systems of Fagor provided with an accessory to process control (laser) based on optimized parameters database and scalable to any machine with a CNC control of Fagor Automation.

It should be noted that it is also provided a platform of LMD process control with optical and thermographic process sensors):

- to CNC advanced environments

- with LABVIEW platform control

- connectable to platform or IoT infrastructure



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• Laser disco 5kW, Laser Nd-YAG 3 kW, diode laser 3kW, fiber laser IPG 1kW

Different types of lasers

• Fix and floating optical head

Different types of heads

• Powder feeder of 2 units with heating

Powder feeder of 2 units with heating and able to be remote connected

• Four robotized cells: ABB robot, robot ASEA IRB 2000, Robots FANUC 1 and FANUC 2

ABB robot, robot ASEA IRB 2000, Robots FANUC 1 and FANUC 2

• Arc welding processes: PAW, TIG, CMT

PAW: Plasma Arc Welding TIG: Tungsten inert gas welding CMT: Cold Metal Transfer welding





Materials for 3D/AM


Parts manufacturing by LMD

Possibility of programing paths in CAM environment (for cartesian systems and robots, TEBIS, Autodesk, power mil,…). Prototypes manufacturing and final part with high added value (including post-processing) (steel, Ti, Ni alloy, Al). Parts manufacturing with controlled coating with high performances. Geometrical distortion control in complex part manufactured by additive manufacturing technologies of high deposition.

Smart process controlling and temperature and melt pool size monitoring during LMD process

It is provided a thermographic camera (camera and pirometer) and other CCD camera for temperature and geometry of the met pool monitoring, respectively, to an optimal LMD process control (closed-loop). Process parameters´ optimization including shielding gas in the case of WAAM processes.

Additive manufacturing integration in industrial productive processes. Hybridization of processes.

Connect machines of different processes (LMD and/or WAAM) with subtractive (machining, etc) to improve the efficiency of the productive process.



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Surface treatments and repairs of parts manufactured by LMD

Optimized surface treatments development to obtain optimal final properties, taking into account the metallurgy of each alloy, thermal history of the deposition process and application requirements.

Bring technology to the companies and related opportunities and risks.

Bring additive manufacturing technology close to the environment and basque companies and this potential benefits and business opportunities. Orientation about achievable mechanical properties and microstructure.

Test (materials, characteristics,…) including powders and assess their processability

It is provided an open platform to develop parameters and process for new materials and the possibility of characterizing them until achieve the optimization.

Test ICT systems related to simulation and CAD-CAM-CA_x in a controlled environment prior to their commercial deployment

Test ICT systems related to simulation and CAD-CAM-CA_x in a controlled environment prior to their commercial deployment. Possibility of testing data platforms to process control (Data Analysis and Big Data).

Training

Access to people to different levels, from technicians, engineers to other profiles for their introduction and training in technology to achieve an adequate technological criterion.


IK4-LORTEK Contact Person:María san sebastiá[email protected]



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Semi-industrial pilot plant for (electro)chemical surface fi nishing

Semi-industrial pilot plant for (electro) chemical surface fi nishing that allows reducing the surface roughness up to 60% on metallic parts with relatively complex geometries, manufactured by AM. The resulting surface is clean and has a high gloss. By means of this asset it is also possible to machine or shape certain areas of a piece.

The pilot plant consists of:

• Tanks up to 250 L capacity with several heaters, cooling coil, mechanical agitation, air agitation, the possibility to place counter-electrodes in diff erent positions, level probe, lid and suction hood.

• Rectifi ers capable of applying a wide a range of voltage/current

• Equipment for the evaluation of surface roughness (currently off -line, expected to acquire

in-line characterization equipment)

• Equipment for additional surface characterization (thermography, corrosion, wettability, brightness, mass loss, changes in geometry of the piece, etc.)

• Planned to acquire electrochemical simulation software that allows to quickly identifying the initial parameters of the process depending on the requirements, the geometry and the type of material to be post-processed.

• Planned to acquire a monitoring and control software for the electrochemical pilot plant that facilitates the connectivity of the plant with a MES from which the manufacturing plant of the components as a whole will be managed.


• Electrolytic tanks

Electrolytic tanks up to 250 L of capacity with two heaters, cooling coil, mechanical agitation system, air agitation system, the possibility to place counter-electrodes in diff erent positions, level probe, lid and suction hood.

• Rectifi ers

Rectifi ers capable of applying a wide a range of voltage/current



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Post process


Training

Practical and theoretical training in post-processing and surface finishing technologies.

Advice for scaling and industrial feasibility study

Industrial and technical feasibility studies of the processes developed in this asset

Development and optimization of post-processing of AM parts. Prototype obtaining

Roughness control of metallic parts manufactured by AM with relatively complex geometries (roughness reduction of up to 60%). By combining this asset with others available, a roughness reduction of up to 95% can be achieved. Surface cleaning: The surfaces treated by electrochemical methods are clean and free of contaminants. Improved corrosion resistance: Electropolishing processes improve the corrosion resistance of stainless steel materials.

Process monitoring and control

Once the monitoring and control software has been acquired, the (electro)chemical post-processing plant can be connected to the additive manufacturing processes and will have input on the specific requirements of the part or component to be treated.


CIDETEC Contact Person:Gemma Vara [email protected]

• Equipment for the evaluation of surface roughness

Equipment for the evaluation of surface roughness (perfilometre, confocal microscope, AFM) and equipment for additional surface characterization (thermography, wettability, brightness, weight loss, changes in geometry of the piece, corrosion, etc.)

• Equipment for electrolyte control and regeneration systems

Equipment for electrolyte control and regeneration systems (ICP, ion chromatography, automatic titrators, microfiltration equipment ... etc.)

• Electrochemical simulation software

Electrochemical simulation software that allows to quickly identifying the initial parameters of the process depending on the requirements, the geometry and the type of material to be post-processed.



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ADDITOLA: Laser metal Cladding cell LMD based on ABB robot and two work tables

The ADDITOLA laser metal cladding cell consists of an ABB robot with six degrees of freedom and two work tables, one large fixed one (1100x700) for working on heavy-weight and bulky components and another smaller one (ABB) with 2 additional degrees of freedom (+/- 180° of the arm and infinite on the chuck), with a maximum load capacity of 500 kg, for creating more complex geometries (see image above). This installation makes it possible to create new parts from a metal base, repair high added-value components, add layers of different materials such as coatings and create new geometries on other base parts, using different metal materials in powder form. For post-processing of the parts, a set of machining centres is available in the process workshop.

The cell is isolated from the outside environment by means of an enclosure that complies with all the safety regulations required for this type of processes (see image above). Programming and control of the entire system is done with the ABB joystick. The installation consists of the equipment and components listed in the following table.

The creation of the solid is achieved by melting the metal powder, when the laser focalisation through the optical fibre converges at one point with the metal powder fed from the OERLIKON powder dispenser and conveyed by argon gas, and the argon itself.


• PRECITECH laser head

• ABB IRB 2600 industrial robot and its control device

• 2-axis rotary table

• Laser generator ROFIN FL010 of 1kW and LOTEC cooling equipment

• OERLICON TWIN metal powder feeder with twin tank







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Process innovation for AM and technical-economic feasibility study of processes

Analysis and technical-economic validation of alternative manufacturing processes to the current ones, such as additive manufacturing, both for making and repairing parts, as well as for geometric modification of existing parts. The service is developed jointly with the customer.

Studies of industrialisation, first series and interdependence with other processes

- Study of the industrialisation of a new part reference or redesigned part using additive manufacturing technology.

- Integration of additive manufacturing processes in the productive chains, merging them with the current processes.

Search for suppliers for part production using additive manufacturing

After defining the industrialisation process, either using only AM technology or merged with other processes, search for suppliers for series production.

Disseminating technology through technical or general conferences

Disseminate additive manufacturing technology as a whole (process, machines, capacities, markets, etc.) holding theoretical-practical workshops, with the asset itself as a work tool.

Specific training addressed at Vocational Training teachers

A set of educational activities related to Additive Manufacturing technology aimed at improving competences of teachers. The asset is the basic training tool.

Specific training addressed at Vocational Training students

Training activities related to Additive Manufacturing technology in Vocational Training. The asset is the basic training tool.

Specific training for company technicians through job training

Training related to Additive Manufacturing technology aimed at technicians from companies that do currently not have the technology, and merging this technology in their production processes would bring them a competitive advantage, or at companies that already work with this technology.


IMH - Fundación para la Formación Técnica en Máquina-Herramienta/Makina Erreminten Hezkuntza Teknikorako Fundazioa Contact Person:Xabier Cearsolo [email protected]



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Metal cladding cell (Robot IRB-1600 ABB) and plasma welding machine SBI (PMI-280B)

Metal filler cell by means of plasma welding processes with wire, on an ABB robot with a two-axis positioning mechanism for creating new parts, repair of high added-value components and addition of geometry on base parts. The

cell is secluded from its environment to ensure operator safety. Programming of cladding material paths, through the robot, is performed by the CAM PowerMill software.


• ABB IRB 6600 industrial robot and IRC5 control device

• IRBP-250 two-axis positioning mechanism 2007

• Plasma welding machine with wire filler (SBI - PMI-280B model)

• AbiPlas-250 plasma welding torch 2016










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Studies of industrialisation, first series and interdependence with other processes - Study of the industrialisation of a new part reference or redesigned part using additive manufacturing technology. - Integration of additive manufacturing processes in the productive chains, merging them with the current processes. - Product developers - Machinery and equipment manufacturers - Parts manufacturers - Suppliers of finished parts NO













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Realizer 250 Selective Laser Melting (SLM) 3D metal printer

Realizer 250 Selective Laser Melting (SLM) 3D printing machine, prepared for the manufacturing of metal parts from scratch, with powder bed fusion technology, to obtain extremely complex geometries (including internal cavities and thin walls) with reasonably good accuracy and surface qualities. The maximum construction volume is 250x250 mm2 with a height of 300 mm. In addition

to the machine, there is a powder-filtering, drying and storage system. The materials that can be used are various: tool steel, titanium V4, stainless steel 306L, aluminium, Inconel, etc.

The installation has sensors for external pick-up of the main process parameters.


• SLM Realizer 250

• Vibrator machine with ultrasound and filter mesh

• Memmert drying oven

• Powder/water vacuum cleaner







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Studies of industrialisation, first series and interdependence with other processes















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Geometric processing and computational geometry software library

Geomlib® is a high performance geometric processing software library, designed to be applied on industrial conditions and requirements. Its implementation allows manipulation and processing of different geometric, topologic and parametric representation levels of 3D objects, including point clouds, triangular mesh and/or CAD surfaces.

Geomlib® includes last generation algorithms to work with these representations in a unified framework. This approach simplifies the development of personalized CAD/CAM applications, as well as other applications with

geometric processing needs, where performance and precision are key success factors. The active allows providing services throughout the manufacturing value chain, from component design phases (with geometric adaptation focused on specific additive manufacturing processes), as well as during dimensional quality control phases after the aforementioned manufacturing process.

Geomlib® asset is now being used as the geometry processing core of a commertial metrology software distributed by the metrology expert company Sariki: SK-Inspect


• High precision laser triangulators

High 3D reconstruction system based on laser triangulation

• Structured light based scanners

3D reconstruction system based on structured light,


Design dor AM and Digital pre-procesing Supporting technologies and processes

AM Digital Chain



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Dimensional Control

Dimensional verification in additive manufacturing processes.

Geometric optimization

Adaptation of an original model from common manufacturing to additive manufacturing. For a better use of manufacturing features by material deposition, it is necessary or possible to make more efficient part designs. This efficiency can be obtained using by geometric transformations or adaptations.


VICOMTECH Contact Person:Iñigo [email protected]



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Manufacturing Processes Workshop IMH-ASMAOLA

Mechanical workshop equipped with several production machines, all of them for stock removal..

These machines, apart from being used for machining of prototypes, experimental machining trials for time and cost optimisation, pre-series

for validation or approval of parts/products, etc., can also be used as tools for post-processing of manufactured parts using additive manufacturing technology. They therefore are a complement in the use of assets for Additive Manufacturing.


• Multi-process machining centre Ibarmia ZVH 38/L 1600 with horizontal and vertical turning chucks

• Multi-process machining centre Danobat TM-750 with horizontal turning chuck

• 5-axes machining centre Kondia Seaska, 24,000 rpm and +/- 0.005 mm precision (Dim. Part: 660x400x510) and 3-Axes machining centre Kondia P60-V2, +/- 0.003 mm precision (Dim. Part: 600x400x350)

• Wire spark erosion machine ONA AF-35.Travel: 600x400x400 y 120x120 in U-V. Resolution 0.001 mm

• Exterior and interior cylindrical grinder Danobat LG-600-P2


Machining processes complementary to the additive manufacturing technology

Performance of machining operations for post-processing required in references/parts manufactured by additive manufacturing.

These assets provide numerous services related to the machining processes, and have been used in numerous projects, both in innovation and industrial projects.

- Optimisation of process times and costs. - Machining of pre-series for subsequent validation.- Definition of the industrialisation process on IMH machines (without any need to interrupt production

at the production plant of the customer) and implementation on the production line of the customer.- Ad hoc training.



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