Additive Manufacturing using Metal Pilot Line (MANUELA)

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.

Partner organizations

  • Cardiff University (Academic, United Kingdom)
  • Stiftelsen Chalmers Industriteknik (Private, Sweden)
  • Polytechnic University of Turin (Academic, Italy)
  • Electro Optical Systems OY (Private, Finland)
  • Qioptic Ltd. (Private, United Kingdom)
  • University of Erlangen-Nuremberg (FAU) (Academic, Germany)
  • RISE Research Institutes of Sweden (Research Institute, Sweden)
  • OEB S.r.l. (Private, Italy)
  • Siemens industrial turbomachinery (Private, Sweden)
  • OSAI Automation Systems S.p.A. (Private, Italy)
  • Biomedical Engineering s.r.o. (Private, Slovakia)
  • Höganäs (Private, Sweden)
  • Centre suisse d'électronique et de microtechnique (CSEM) (Research Institute, Switzerland)
  • Ruag Slip Rings AS (Private, Switzerland)
  • MSC Software Corporation (Private, Germany)
  • Chalmers (Site, Sweden)
  • Chalmers (Publisher, Sweden)
  • Enel (Private, Italy)
  • Amires s.r.o. (Private, Czech Republic)
  • Federal Institute of Metrology (METAS) (Research Institute, Switzerland)
  • ABB Sweden (Private, Sweden)
Start date 01/10/2018
End date 30/09/2022

Funded by

  • European Commission (EC) (Public, Belgium)

Published: Thu 03 Sep 2020.