MICRO-FAST A FAST process and production system for high-throughput, highly flexible and cost-efficient volume production of miniaturised components made of a wide range of materials

Summary

The main exploitable results achieved in this project are as follows

MACHINE SYSTEMS AND SUBSYSTEMS

The core project result is represented by Micro-FAST machine system for the production of high quality components. It is first kind of the machine developed specifically for the manufacture of miniature to micro-sized bulk components with controlled micro-structures, using a wide range of powder materials.

The innovative and fast process combining micro-forming and electrical-field activated sintering technology (Micro-FAST) and fully automated machine system are expected to generate significant impacts in the manufacturing sector and component users. To accompany this several individual ancillary sub-systems related to the press have also been developed, including that for powder feeding, robotic handling of the die-set, ejector for the formed parts, laser die-cleaning and inspection system. These will also be exploited for other applications in different industrial environments.

MATERIALS AND TOOLING

Several types of high-quality powders have also been developed that can be used in the FAST applications as well as in other powder metallurgy processes. Nanostructured metal-based and ceramic powders are produced with different techniques able to deliver controlled and homogenous chemical and structural composition and optimized flowability, leading to high quality formed parts produced. Correspondingly, advanced surface treatment and coating techniques for micro-tooling have been developed for high-temperature applications such as Micro-FAST processes, including active-screen plasma co-alloying technology enhancing oxidation and wear resistance and reducing friction coefficient of the tool surfaces.

In addition to these, first kind of multiscale modelling technique and software modules for the modelling of electrical-field activated sintering and forming have been developed, which is able to link modelling of micro-scale electro-plasticity, diffusion bonding and bulk-material deformations to predict the material behaviours during Micro-FAST.

COMPONENTS

High-quality parts produced are expected to have impacts in the field of miniaturised products/systems, both for users and manufacturers. The production of these parts through the Micro-FAST process and the machine will result in better performances, more economical gains and enhanced industrial competitiveness, compared to the current solutions.

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Web resources:	http://www.micro-fast.eu https://cordis.europa.eu/project/id/608720
Start date:	01-09-2013
End date:	28-02-2017
Total budget - Public funding:	7 512 973,00 Euro - 5 349 843,00 Euro

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Original description

The aim of the project is to develop a completely new manufacturing system for the volume production of miniaturised components by overcoming the challenges on the manufacturing with a wide range of materials (metallic alloys, composites, ceramics and polymers), through: (i) developing a high-throughput, flexible and cost-efficient process by simultaneous electrical-forming and electric-fast-sintering (Micro-FAST); (ii) scaling up the process to an industrial scale; (iii) further developing it towards an industrial production system for micro-/nano-manufacturing. These will be enabled/supported by developing: (i) a new machine concept: Micro-FAST CNC Machine; (ii) an innovative inline monitoring and quality inspection system; (iii) innovative multiscale modelling techniques for the analysis of the micro-structural behaviours of materials and its interactions with the production processes; (iv) new tooling techniques for high-performance tools, and (v) high-performance nano-material systems. The whole development will take into account energy savings, cost and waste reduction, and recycling issues which will be studied thoroughly through an expertise Life-Cycle Assessment.
The development should lead to substantial improvements in the manufacture of components at micro and nanoscale with a good balance on cost and performance. The consortium seeks: reduction of the overall manufacturing cost by 50-100%; energy consumption by more than 30-50%; achieving full-density (100% density) components; direct economic gains for the SME participants of up to 5-25%.
The whole development will support the EU-wide product innovations involving use of miniature and micro-components in many manufacturing sectors and, especially with difficult-to-cut and difficult-to-form materials. Adopting the production system in industry should help the EU manufacturing sectors to gain new technological and business competiveness significantly.