CLASCO. Climate Neutral and Digitalized Laser Based Surface Functionalization of Parts with Complex Geometry
HE HORIZON-CL4-2021-TWIN-TRANSITION-01-02
Grant agreement ID: 101091373
- PROJECT DESCRIPTION:
In the coming years, European industry must take on the challenge of adopting clean, climate-neutral industrial value chains, producing sustainable products. The adoption of digital systems will radically transform the industry, with products and services enabled by innovative production processes. In particular, fully digitalized laser-based additive manufacturing methods are highly versatile and can therefore be implemented in different industries. In addition, energy and material waste are saved compared to conventional manufacturing, and design optimization can also be achieved. However, these parts also require additional surface treatments, which currently consume a lot of energy and material, increase costs, and harm the environment. Furthermore, new concepts must be developed to increase the added value of additive manufacturing (AM) parts, for example, by producing advanced surface functionalities in critical applications. The main objective of the CLASCO project is to develop a universal, digitalized, laser-based post-processing route for creating functionalized AM parts with complex shapes.
While complex parts will be produced using laser powder bed fusion, laser polishing and laser surface microstructuring using direct laser interference patterning will be combined into a single manufacturing system. This route will replace several resource-intensive processes, reducing environmental impact. The implementation will allow for the replacement of environmentally harmful standard methods and even for improved performance. In addition, various online monitoring methods will be implemented, specifically plasma sensors and infrared cameras. In this way, it will be possible to obtain a virtual representation of the process for each piece (digital twin), creating a completely digitalized product. The project’s impacts will be analyzed to optimize the sustainability of processes and products throughout their entire life cycle.
- OBJECTIVES: Functionalization of 3D parts manufactured by Additive Manufacturing using laser polishing and interference patterns, to reduce coatings and chemical treatments, with the entire corresponding sensorized process.
- DURATION: 01.01.2023 – 06.30.2026
- PARTNERS THAT MAKE UP THE CONSORTIUM AND THEIR LOGOS
Coordinator:
Partners:
- CATEC ROLE:
CATEC will design and manufacture test specimens using additive laser powder bed fusion technology in Ti64 and Scalmalloy® alloys with different geometries. It will begin with flat surfaces and include various complex features to parameterize the surface functionalization laser, as well as analyze the ability of laser processing technologies to address complex structures.
The demonstrators will then be analyzed and designed in detail to optimize their weight and performance using FEM and analytical part analysis to predict the demonstrator’s structural and/or functional behavior and design it appropriately. Finally, the different demonstrators are manufactured for the structural validation of the concept.
- FEATURED TECHNOLOGIES:
- Metal additive manufacturing by laser powder bed fusion
- Post-processing by laser polishing and laser surface microstructuring with interference patterns
- Online monitoring with infrared cameras and plasma sensors
- Digital twin
- Life cycle analysis
- PROJECT WEBSITE: https://clasco-project.eu/
Funded by:
