InShaPe – Green Additive Manufacturing through Innovative Beam Shaping and Process Monitoring
Motivation
In many industrial fields, the demand for customized high-strength, lightweight, and mechanically highly resilient metallic components is increasing. A promising manufacturing process for these components is additive manufacturing and especially the powder bed fusion using a laser beam (PBF-LB/M). The process is yet often not competitive due to considerably high costs and slow processing speeds compared to other manufacturing technologies.
Goal
The overall goals of the project are to increase the production rate by the factor of 7, reduce the costs by 50 %, reduce the energy consumption by 60 %, and reduce the waste by 30 % in compared to a reference workpiece produced without the process improvements developed within InShaPe. Mainly two technologies should be researched and developed. First, beam shaping should be used for increasing the process speed while reducing the melt pool dynamics and the spatter generation. Second, multispectral imaging shall be installed to observe the melt pool. From the multispectral images, the absolute temperature as well as additional information about the melt pool and of the surrounding area should be determined using Machine Learning. The multispectral imaging shall also be used to establish a closed-loop control of the shape, the power, and the velocity of the laser beam during the process and applied the setup parameters according to the process.
Consortium
TUM – Professorship of Laser-based Additive Manufacturing, EOS GmbH, Oerlikon AM Europe GmbH, Eindhoven University of Technology, SILIOS Technologies, BEAMIT Group, Aenium Engineering, AMEXCI AB, Bavarian Research Alliance GmbH, Technion – Israel Institute of Technology
Acknowledgment
The iwb would like to thank the European Union for funding this project under the grant number 101058523 as well as all the project partners.
Acknowledgment
The iwb would like to thank the European Union for funding this project under the grant number 101058523 as well as all the project partners.
Project details
| Duration | 01.06.2022 – 31.05.2025 |
| Project partners | TUM – Professorship of Laser-based Additive Manufacturing, EOS GmbH, Oerlikon AM Europe GmbH, Eindhoven University of Technology, SILIOS Technologies, BEAMIT Group, Aenium Engineering, AMEXCI AB, Bavarian Research Alliance GmbH, Technion – Israel Institute of Technology |
| Project management | European Union |