Technological Solutions

The patented Shape-From-Shadow (SFS) method (EP4015987A1) employs laser triangulation with a unique approach—projecting a shadow pattern. This active technique measures 3D geometry, focusing on laser metal deposition. Pulsed laser, synchronized with camera exposure, eliminates process radiation influence. Height measurement involves processing images with a Python algorithm, calculating pixel differences on the track or liner. Validated for direct energy deposition processes (LMD or WAAM), this method has been published in a refereed scientific paper.

Hybrid multimaterial additive manufacturing represents an evolution in advanced manufacturing processes, integrating different technologies to produce optimized industrial components.

LORTEK's extensive experience in additive technology metal processing methods with aluminium alloys, titanium, nickel, steels (stainless, tool steels) and difficult to process alloys, has facilitated the development of material-specific parameter windows, guaranteeing minimum defects (<0.1%). Specific strategies for massive parts, thin-walled or Triple Periodic Minimal Surface (TPMS) lattice structures have been developed, forming a library of parameters for various applications.

Laser cell consisting of a Kuka Reis Gantry system with a 7 m long by 4 m wide path; SCANSONIC RLW-A scanning head with joint tracking and the possibility of using two types of lasers: TRUMPF 5 kW disc laser and COHERENT fibre laser with 6 kW ARM technology.

Algorithms to optimise complex problems, adjusting parameters such as geometry, material properties or loading conditions, with the aim of minimising or maximising target functions, such as cost, weight, performance or relevant metrics of the system to be studied.

At LORTEK we have extensive experience in welding process modelling, additive processes, structural calculation and thermal cycle analysis used to represent complex systems and with the capacity to adapt to different situations and design requirements of industrial products and processes, as a tool to simulate extreme conditions and preventive detection of defects.

There are several active thermography techniques used for defect detection. All of them are based on the same fundamentals: a sample or component is exposed to an external excitation source and the propagation of the induced heat is captured with a thermographic camera, analyzing the temperature gradients on the surface for the detection of surface and sub-surface anomalies. 

In-house procedure to characterise incoming powders, with significant improvements in the quality of samples processed by additive technologies: Analysis of particle size distribution (PSD), quantification of powder morphology by SEM image analysis and process to quantitatively measure the internal porosity content of particles. 

At LORTEK, we are actively dedicated to reducing consumption of resources, both time and materials. New materials pose challenges in our additive technologies due to parameter customisation. Our methodology is based on the group's expertise and high impact studies, identifying key parameters to optimise processes and achieve manufacturing efficiency.

The advanced rotary friction controller is an innovative technological solution that LORTEK has developed in collaboration with BERKOA, a company specialising in friction welding solutions. This controller enables high quality, high strength joints between similar and dissimilar metallic materials using a controlled application of rotary motion and axial pressure.