Imagine 3D printing metal parts like using a high-tech glue gun that can change the shape and intensity of its heat beam on the fly. Instead of a static beam, this system adjusts itself in real-time to prevent bubbles and cracks in the metal. It's like having a smart sensor that fixes mistakes while the part is still being built, ensuring the final piece is as strong as a traditionally forged part.
Metal 3D printing often suffers from internal stresses, porosity, and material anisotropy, leading to high scrap rates and inconsistent part quality. These issues make it difficult for additive manufacturing to compete with traditional methods in high-volume industries.
An adaptive multi-laser-beam system with real-time monitoring (multi-spectral imaging and thermography) and physics-based models to control the melt pool.
If you are an aircraft component manufacturer dealing with material imperfections in Ti-6Al-4V alloys — this project developed adaptive multi-laser technology that can reduce defects by ~50% and lower material waste by 10-50%.
If you are a marine engineering firm dealing with distortions and internal stresses in large metal parts — this project developed closed-loop control and beam shaping that can lead to 10-33% in cost savings.
If you are a vehicle parts supplier dealing with slow production speeds and high scrap rates — this project developed a system that can increase process productivity by up to 100%.
The project aims for 10-33% in cost savings through increased productivity and energy savings.
Yes, the technology is being tested across three sectors ranging from low-volume high-value parts to high-volume low-cost production.
Based on available project data, the sub-technologies developed in the work packages will be commercialized, while end users will integrate the technologies into their processes.
It reduces porosity and defects by ~50% by adjusting the laser beam temporally and spatially during the build process.
The project projects a reduction of 5 million tons of CO2 emissions per year and a 15% reduction in greenhouse gases.
The consortium is heavily industry-driven with a 54% industry ratio, comprising 7 industrial partners and 5 SMEs. This strong commercial presence, combined with 4 research centers and 1 university across 7 countries, suggests the project is focused on market application rather than pure theory, specifically targeting the aerospace, maritime, and automotive supply chains.
Contact SINTEF AS in Norway for technology licensing and partnership opportunities.
Contact SciTransfer to connect with the ALABAMA consortium for adaptive laser integration.
