Technological Solutions

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.

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.

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

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. 

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.

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.

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. 

Tool designed to protect reactive materials at high temperatures in DED additive technologies. Attached to the welding torch, it isolates the hot area from air, preventing oxidation. It includes a micropyrometer for temperature measurement and protection adjustment. Unlike closed chambers, it adapts to parts of any geometry and size.

Cyber-physical systems (CPS) are networks of interconnected nodes, virtual programmes with specific functions, such as data capture, analysis in AI models or custom code, that can run on any device. They offer flexibility and adaptability to a variety of tasks, through an interface that facilitates quick switching without altering the underlying programming.