Sustainable Materials and Manufacturing Processes

We promote industrial sustainability through knowledge and innovation in new advanced metallic materials, as well as through the design and digitalization of metal additive manufacturing processes (PBF-LB) to produce highly efficient, functional, and defect-free products and components.

We develop digital technologies that enable smart manufacturing, including manufacturing strategies and monitoring systems for real-time quality control using artificial intelligence.

Materials

We research into the performance and characterisation of materials and joints during manufacturing and service life in standard and extreme conditions.

PBF-LB

We design products for different industrial sectors and develop new materials, parameters and process methodology with state-of-the-art equipment in laser beam powder bed fusion (PBF-LB) and selective laser melting (SLM) technology, supported by our own digital monitoring and quality assurance solutions.

Projects and success stories

We obtain and develop knowledge and capabilities for application to practical, real-world challenges with the help of technology.

ROLIAC - Robust and light AM components for military systems

ROLIAC enables lightweight military-grade part design and manufacture, leveraging additive manufacturing (AM) for EU defense. Key benefits include robust supply chains, lightweight high-performance components, and use of novel materials. ROLIAC focuses on generative design, rapid production, and robust quality control, demonstrated in ground, air, and space applications

ALENCO - Development of SLM process for precipitation-hardening alloys for high performance aeronautical components

Development of additive manufacturing for high performance materials, replacing nickel alloys in aeronautics. Objectives include obtaining dense parts by PBF-LB, applying specific heat treatments, adapting design with DfAM concepts, ensuring quality with monitoring, and validating parts with inspections. Additive Manufacturing solves problems associated with microfusion, simplifying processes and reducing rejects caused by deformation.

LIGHTBEE - Development of Lightweight Battery Carriers for EV Energy Units

The LightBEE project addresses a vital challenge: optimizing battery carrier design for manufacturability. Integrating key manufacturing technologies, it aims to create an advanced battery carrier with lightweight construction, cost-effectiveness, eco-friendly manufacturing, and enhanced crashworthiness. The goal is to overcome barriers in designing high added-value components, achieving a lighter, safer, cost-effective, and environmentally friendly carrier through the use of lightweight materials, multi-material solutions, and advanced joining techniques. This approach marks a significant step towards sustainable and efficient electric vehicles.

HIPERION - Generation of knowledge and capabilities for new space technologies and future planetary missions

HIPERION promotes research in space technology and science to strengthen the sector weight in the Basque autonomous community. Based on high reliability and low weight standards, space research is taking the lead with applications in industry, energy, health and climate change. Solving engineering challenges while developing space technologies is promoting European competitiveness. This project tackles advanced manufacturing, materials, composites, coatings, control systems, avionics and optical path technologies.

FORTEC - Formación en tecnologías de unión para la fabricación de componentes de las funciones battery box y door ring de vehículos eléctricos

Renault España lidera este innovador proyecto para la creación de un ecosistema industrial centrado en la fabricación de vehículos eléctricos y conectados aglutinando 31 iniciativas entorno a la descarbonización, la conectividad y la movilidad como servicio.

Advanced Equipment

We have a full range of singular technological infrastructures for advanced research, design and development of metal additive manufacturing projects.

SMARTLAB laboratory, with a cell for a data-driven approach towards additive manufacturing processes, and integration of inspection and control systems. Samylabs Alba 300.
Material characterisation laboratory: Granudrum, SEM, PC/Optical
Advanced software for topology optimisation, design, simulation and preparation of manufacturing processes: Inspire, Optistruct, Tosca, 3D Experience, Magics, QuantAM, Sulis.
Fully equipped laboratory for characterisation and testing of materials and welded joints - sample preparation, optical microscopy and SEM+EDS+EBSD, mechanical testing, corrosion tests, etc.
Additive manufacturing cell: technology development based on a data-driven approach in additive manufacturing with Samylabs Alba 300 SLM machine.