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Optimizing Metrology Integration Into AM

The major goal of the INTEGRADDE project is to develop a end-to-end Digital Additive Manufacturing (AM) solution, based on Directed Energy Deposition (DED) technologies (i.e. Laser Metal Deposition (LMD) for manufacturing of complex geometries in medium-sized components with higher accuracy, and Wire-Arc Additive Manufacturing (WAAM) for simpler geometries with higher deposition rates) enabling a cyber-secured bidirectional dataflow for a seamless integration across the entire AM chain.

The goal is to develop a new manufacturing methodology capable of ensuring the manufacturability, reliability and quality of a target metal component from the initial product design.

Integradde combines research on building strategy optimization, multi-scale and multi-physics modelling, hardware-independent building process, automatic building strategy generation, online self-adaptive control and inline quality assurance for the manufacturing of certified metal parts, addressing mass customization manufacturing approach.

The project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement No 820776.

The principle steps that the Integradde project will take are to develop novel multistage pilot plants based on DED processes, hybridizing AM with previous and subsequent processes for the manufacturing of several certified metal parts. Develop novel data-driven pipeline supporting the design, simulation and production planning for additive manufacturing. Implement a Quality-by-Design (QbD) manufacturing strategy, based on real-time control systems, inline quality control systems and minimized consumption of raw materials. The Integradde project also wants to Implement a digital end-to-end engineering concept and demonstrate Integradde approach in several pilot lines for the manufacturing of certified metal parts.

Integradde has gathered over 25 European companies and institutions that willing work together to reach the integradde goals and include Datapixel, NIT, The Coimbra University, the University of Sheffield, Aimen, Acerlor Mittal, Bureau Veritas, Corda, DIN and more.

Datapixel, part of Innovalia Metrology, will supply Integradde with data collection and analysis systems, endorsed with cognitive abilities gaining knowledge from overall process, will assist in the quality verification but also design and manufacturing of new components, addressing mass customization manufacturing approach which will provide 3D dimensional inspection solutions, virtual metrology, in line inspection and robot guidance systems. The Quality assurance duty will allow the project not only to have the best outcome of the part but also to correct and give information on how the part is being made and being able to adjust the production. Datapixel has provided the Integradde project with its M3 Hybrid, a high-tech metrology solution formed by a bridge CMM, optical sensor and measuring software that will scan and digitize the parts, providing digital copies of each part and making it easy to measure, examine and share measured data.

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