Success Stories

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.

The project addresses the need to implement high-speed FSW (Friction Stir Welding) in the automotive sector, especially in the context of electric mobility (e-mobility). The growing demand for electric vehicles requires more efficient and faster manufacturing processes without compromising quality. FSW welding presents an advanced solution for joining lightweight materials like aluminum, which is crucial for reducing weight and improving the energy efficiency of vehicles.

Develop and implement new systems for advanced control of the rotary friction welding process. To achieve this, a new process control system will be developed as well as critical sub-systems capable of providing the performance characteristics demanded by highly demanding applications from the control point of view in the manufacture of components by rotary friction welding.

To implement an inspection system for thermocouples and magnetic groups in Orkli’s Gas Safety range, critical components that require rigorous quality control. Traditionally, this inspection was performed visually by operators, a labor-intensive process due to the small size of the parts and the high production volume.

The project addresses the need to lighten structures through the welding of aluminum and steel components. The solution involves designing and manufacturing structures using bimetallic materials with explosion welding, arc welding, and Friction Stir Welding (FSW). LORTEK contributes by developing the FSW process, including tools and specific parameters, in collaboration with CAF R&D.

Digitalisation of a tube manufacturing line for product quality monitoring and improvement. Key process variables such as temperature and forming pressure will be obtained. The quality of the current sensor system will be assessed and additional sensors for deeper understanding will be considered. Data will be integrated into a digital platform for real-time monitoring and history log access. This project will facilitate the identification of manufacturing patterns, detecting improvements and accurate process optimisation.

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.

The project addresses environmental challenges in the production and lifecycle of aircraft, from manufacturing to maintenance and final disposal. It focuses on developing advanced materials and innovative technologies to reduce the environmental footprint. This includes creating new materials, processes, and recycling methods for more eco-friendly manufacturing. Laser welding and advanced sensors ensure efficiency and quality in large aeronautical structures, in collaboration with industry companies.

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.

Sectors such as automotive, rail, shipbuilding and architecture are looking for customised structures, although the current limitations of additive manufacturing do not allow this. To meet this challenge, we propose developing advanced materials based on thermosetting composites, already used in aeronautical and automotive industries. The aim is to achieve layer-by-layer bonding with efficient curing to produce large parts using additive manufacturing processes.