MANUELA Additive Manufacturing using Metal Pilot Line

Summary

Metal additive manufacturing (AM) allows, by enabling use of advanced design, production of high added value components, at levels that cannot be reached with conventional manufacturing technique.

Still, the AM-based manufacturing sequence implies large amounts of critical steps ? design for AM, AM fabrication, post processing, etc. ? compared to conventional production sequences. Presently, the key competencies related to these steps are either not fully implemented at industrial level (process quality monitoring) or dispersed geographically with poor connection between different steps.

Relying on two major AM technologies (LPBF: Laser Powder Bed Fusion and EBM Electron Beam Melting), MANUELA aims at deploying an open-access pilot line facility, covering the whole production sequence, to show full potential of metal AM for industrial AM production.

At first, careful instrumentation and adaptation of LPBF & EBM machines will allow increased process reliability and speed.

Secondly, the pilot line - including the adapted processes - will be deployed. The hardware layer will integrate novel process quality control monitoring and automated post-AM handling and processing. The line will be fed by design/optimization and AM process simulation workshops. Those workshops will collect continuous feedback from the physical parts of the pilot lines, to increase process reliability and robustness.

MANUELA relies on a consortium composed of industrial end users, suppliers, (material/powder, AM hardware, quality monitoring system, software, automation and post-AM treatment) as well as top research institutes in powder-bed metal-AM, covering full range of AM technology chain for pilot line deployment.

The deployed pilot line will be validated for use cases, covering wide span of applications including automotive, aerospace, energy and medical. To insure sustainability of the deployed line and its open access at project end, a dedicated exploitation plan will be established.

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Web resources:	https://manuela-project.eu/ https://cordis.europa.eu/project/id/820774
Start date:	01-10-2018
End date:	31-03-2023
Total budget - Public funding:	12 448 116,00 Euro - 12 448 116,00 Euro

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Original description

Metal additive manufacturing (AM) allows, by enabling use of advanced design, production of high added value components, at levels that cannot be reached with conventional manufacturing technique.
Still, the AM-based manufacturing sequence implies large amounts of critical steps – design for AM, AM fabrication, post processing, etc. – compared to conventional production sequences. Presently, the key competencies related to these steps are either not fully implemented at industrial level (process quality monitoring) or dispersed geographically with poor connection between different steps.
Relying on two major AM technologies (LPBF: Laser Powder Bed Fusion and EBM Electron Beam Melting), MANUELA aims at deploying an open-access pilot line facility, covering the whole production sequence, to show full potential of metal AM for industrial AM production.
At first, careful instrumentation and adaptation of LPBF & EBM machines will allow increased process reliability and speed. Secondly, the pilot line – including the adapted processes – will be deployed. The hardware layer will integrate novel process quality control monitoring and automated post-AM handling and processing. The line will be fed by design/optimization and AM process simulation workshops. Those workshops will collect continuous feedback from the physical parts of the pilot lines, to increase process reliability and robustness.
MANUELA relies on a consortium composed of industrial end user’s, suppliers, (material/powder, AM hardware, quality monitoring system, software, automation and post-AM treatment) as well as top research institutes in powder-bed metal-AM, covering full range of AM technology chain for pilot line deployment.
The deployed pilot line will be validated for use cases, covering wide span of applications including automotive, aerospace, energy and medical. To insure sustainability of the deployed line and its open access at project end, a dedicated exploitation plan will be established.