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ADALAM · Project

Smart Laser System That Sees and Corrects Mistakes While Cutting Micro-Parts

manufacturingPilotedTRL 6
adalam.eu

Imagine a surgeon who can see exactly what they're cutting in real time and adjust on the fly — that's what ADALAM built for laser manufacturing. Ultrashort pulse lasers can machine almost any material with incredible precision, but tiny variations in the material can throw off accuracy. ADALAM added an inline 3D sensor that watches the surface while the laser works, so the system automatically corrects itself mid-process. The result: zero-defect micro-manufacturing without constant human supervision.

By the numbers
19
consortium partners across 5 countries
95%
industry partners in consortium
9
SMEs in the consortium
EUR 3,764,635
EU contribution to project development
8
demonstrated prototype deliverables
17
total project deliverables produced
The business problem

What needed solving

Laser micromachining can cut almost any material with extreme precision, but small variations in material properties or part geometry cause defects and waste. Without real-time feedback, manufacturers either accept scrap rates or slow down production for manual quality checks. This gap between laser precision potential and actual production accuracy costs money and limits adoption of micro-manufacturing.

The solution

What was built

The project built a complete adaptive laser micromachining system: two generations of inline 3D measurement sensors, an automatic calibration reference system, an active alignment unit with adaptive optics, an external high-resolution measurement head, a process-optimized scanning objective, and adaptive laser processes for both selective defect removal and texture machining — 17 deliverables in total, 8 of which are demonstrated prototypes.

Audience

Who needs this

Precision micro-parts manufacturers with high scrap rates from laser processingMedical device companies requiring zero-defect micro-machined implants or instrumentsWatchmaking and jewelry companies using laser engraving on complex 3D surfacesElectronics manufacturers doing laser structuring on sensitive substratesLaser machine OEMs looking to add adaptive sensing capabilities to their equipment
Business applications

Who can put this to work

Precision Engineering & Micromachining
SME
Target: Contract manufacturers producing micro-components for medical devices, electronics, or watchmaking

If you are a precision parts manufacturer dealing with high scrap rates from laser micromachining — this project developed an adaptive laser system with inline 3D surface measurement that automatically corrects the machining process in real time. Built across 19 partners with 95% industry involvement, the system eliminates defects by scanning surfaces before, during, and after cutting.

Automotive & Aerospace Components
mid-size
Target: Tier 1-2 suppliers producing safety-critical micro-structured surfaces

If you are a component supplier struggling with quality validation of micro-textured or micro-drilled parts — this project created a second-generation inline measurement system that scans complex 3D shapes and automatically aligns machining patterns to each workpiece. With 8 demonstrated prototypes including adaptive defect removal, parts are validated instantly after machining.

Semiconductor & Electronics Manufacturing
enterprise
Target: Companies doing laser structuring, via drilling, or thin-film patterning on sensitive substrates

If you are an electronics manufacturer where thermal damage during micro-processing destroys expensive substrates — this project built an ultrashort pulse laser system with quasi non-thermal ablation combined with fast 3D depth sensing. The adaptive process detects and removes surface defects automatically, eliminating manual inspection steps across the production line.

Frequently asked

Quick answers

What would it cost to implement this adaptive laser system?

The project received EUR 3,764,635 in EU funding across 19 partners to develop the full system. Individual component costs (sensor heads, calibration software, scanning objectives) are not published. Contact the coordinator UNIMETRIK SA for licensing or integration pricing.

Can this scale to high-volume production lines?

The system was designed for inline use — meaning it operates during production, not as a separate lab step. The second-generation inline measurement system and process-optimized high-NA scanning objective suggest it was built with production speed in mind. Scaling to specific throughput requirements would need discussion with the consortium.

What about IP and licensing?

UNIMETRIK SA (Spain, an SME) coordinated the project. With 18 industry partners and 9 SMEs across 5 countries, IP is likely distributed among consortium members. Licensing terms for specific components (sensor, software, adaptive process) should be negotiated with individual partners.

Does this work with existing laser machines or require new equipment?

The project developed modular components — an external measurement head for high lateral resolution, an active alignment unit for beam coupling, and sensor integration based on adaptive optics. This modular design suggests retrofit potential, but integration specifics depend on your existing laser platform.

How accurate is the inline measurement during machining?

The project built both a first-generation and second-generation inline measurement system, plus an automatic adjustable reference path system for calibration. The objective states the system enables 'fast and accurate 3D surface measurements' during ablation. Specific accuracy numbers are not published in the available project data.

What materials can this system handle?

The ultrashort pulse laser ablation process described in the objective can 'machine any material with high precision' due to its quasi non-thermal nature. This includes metals, ceramics, polymers, and composites. The adaptive sensor compensates for material variations that would otherwise compromise accuracy.

Is this technology being used commercially today?

The project closed in June 2018. UNIMETRIK SA, the coordinating SME, specializes in metrology and is the most likely path to commercial access. Based on available project data, there is no published information about current commercial deployment status.

Consortium

Who built it

This is an unusually industry-heavy consortium: 18 out of 19 partners are from industry, with zero universities involved — a strong signal that the technology was built for real production floors, not academic papers. The coordinator UNIMETRIK SA is a Spanish SME specializing in metrology, surrounded by 8 other SMEs and larger industrial players across 5 countries (Spain, Germany, Netherlands, Switzerland, Sweden). The single research organization provides scientific backing without diluting the commercial focus. For a business considering this technology, this consortium composition means the system was designed by manufacturers for manufacturers.

How to reach the team

UNIMETRIK SA is an SME metrology company based in Spain — SciTransfer can facilitate an introduction to discuss licensing or integration options.

Order a report on this consortiumSee UNIMETRIK SA profile →
Next steps

Talk to the team behind this work.

Want to explore how adaptive laser micromachining could eliminate defects in your production? SciTransfer can connect you directly with the ADALAM team and help assess fit for your specific manufacturing challenge.

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