Additive Manufacturing Large Format and Repair Processes

Creation of a network of excellence in AM, integrating the capabilities of four centres of the consortium. It covers the value chain of metal additive manufacturing: design, production, processing, post-processing and advanced testing. It addresses a wide range of metals with SLM, LMD, EBM and WAAM technologies. It studies the integration of Femtosecond lasers. The project excels at training and talent attraction/ the programme's forte is training and talent attraction. AIDIMME, CEIT, FADA-CATEC and LORTEK are designated "Cervera Centre of Excellence" in Additive Manufacturing and receive support from CDTI.

NINFA drives research and development to efficiently and industrialise the aerospace sector in a cost-effective way while maintaining high quality standards. From design to post-processing, in collaboration with the supply chain. In addition, it seeks to apply developments in other sectors such as the medical-dental sector. Focusing on light alloys, cost-benefit analysis, industrialisation and process and material quality, NINFA covers the entire supply chain, including research into heat and surface treatments, process monitoring, mechanical characteristics, non-destructive methods, and distortion modelling for product design.

El proyecto FUTURAMA busca aumentar la fiabilidad y autonomía de las máquinas de fabricación aditiva metálica por deposición de energía directa (DED), reduciendo la necesidad de supervisión constante. Para ello, desarrollará sensores avanzados, modelos de autoaprendizaje y herramientas de simulación que controlen variables críticas como la temperatura y geometría. Aplicado a sectores como el aeronáutico, petroquímico y ferroviario, el proyecto producirá componentes de gran tamaño sin desperdicio, apoyando la sostenibilidad y digitalización industrial de Euskadi y Europa.

The MADISON project, a continuation of CEFAM 2020-2022, aims to enhance participation in the additive manufacturing (AM) value chain. It addresses challenges in AM technologies applied to metals, promotes excellence in training, and attracts talent. It develops strategies for dynamization, transfer, and industrial protection to enhance results. Technically, it fabricates and simulates five materials (Ti64, Cu, Al, steels, and Ni alloys), improves AM technologies and material processability, designs non-destructive inspection methods, and analyzes the sustainability of the processes.

DISCMAM aims to reduce military operational downtimes by utilizing metal AM technologies for on-site spare parts manufacturing. The project develops a secure digital thread for remote assistance, demonstrated through Powder Bed Fusion and Directed Energy Deposition Laser-based technologies. Benefits include eliminating the need for specialized on-site operators, reducing supply time and costs, minimizing non-usage time of critical assets, and optimizing on-site stocks in the EU defense sector.

The project aimed to develop a new advanced manufacturing route for the design and production of LEADING’s EPS2 meter, combining hybrid additive manufacturing with processes such as casting and CNC machining.

WAVETAILOR intends to create a highly intelligent, flexible and reconfigurable laser-based additive manufacturing processes to overcome the current weaknesses in manufacturing geometrically complex multi-material components and assemblies by additive manufacturing. This will provide material savings, increase overall equipment efficiency and minimize defects.

In the life cycle of high-value products or parts, defects arise and need to be repaired. Geometric complexity leads to costly and time-consuming manual operations. The aim is to automatise and optimise material deposition operations to improve efficiency and reduce costs.

TECMADIVA focuses on research and design of innovative solutions for metal AM by directed energy deposition (DED). It prioritises new alloys, multi-material processes, advanced robotics and digitalisation. With 6 activities, it is oriented to sectors such as Steel, Oil & Gas, and Moulds and plastic injection. It includes alloy design, multi-material manufacturing, DED systems with AI, digitalisation, and demonstrations in different end scenarios. Based on a consortium made up of five companies and research centres, TECMADIVA is a multidisciplinary project for the entire process chain.