CUSTODIAN · Project

Custom Laser Beam Shapes That Eliminate Cracking in Welding and Metal 3D Printing

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When you weld metal or 3D-print metal parts with a laser, the rapid heating and cooling often causes cracks — like pouring boiling water into a cold glass. CUSTODIAN figured out how to reshape the laser beam itself so it delivers heat in exactly the right pattern for each specific metal and process, preventing those cracks from forming. Think of it like switching from a garden hose to a precision sprinkler system that waters each plant differently. They built a compact beam-shaping device and a real-time quality control system that watches the process and adjusts on the fly.

By the numbers

consortium partners

countries in the consortium (AT, DE, ES, FR, IT)

SMEs in the consortium

50%

industry partner ratio

total project deliverables

The business problem

What needed solving

Hot cracking is one of the biggest quality problems in laser welding and metal 3D printing. When a laser heats metal and it cools too fast or unevenly, cracks form — leading to rejected parts, costly rework, and production delays. This is especially painful for high-value components made from austenitic steel (automotive exhaust systems) and nickel superalloys (turbine blades, aerospace parts), where a single cracked part can mean thousands in waste.

The solution

What was built

CUSTODIAN built two core technologies: a compact Multi Plane Light Conversion (MPLC) beam shaping device that customizes the laser energy distribution for each specific metal and process, and a closed-loop inline control system using SWIR/MWIR sensors with FPGA architecture for real-time quality monitoring. These were validated for laser beam welding of austenitic steel and powder bed fusion of nickel superalloys.

Audience

Who needs this

Automotive exhaust system manufacturers using laser welding on austenitic steelAerospace companies 3D-printing nickel superalloy turbine componentsEnergy equipment manufacturers using powder bed fusion for high-temperature partsLaser system OEMs looking to integrate smart beam-shaping into their productsMetal additive manufacturing service bureaus struggling with crack-related rejection rates

Business applications

Who can put this to work

Automotive manufacturing

enterprise

Target: Automotive OEMs and Tier 1 suppliers producing exhaust systems

If you are an automotive parts manufacturer dealing with cracking defects when laser-welding austenitic steel exhaust components — this project developed a beam-shaping system specifically tested on that exact application. The technology customizes the laser energy distribution to prevent hot cracking during welding, which means fewer rejected parts and less rework. The closed-loop control system with SWIR/MWIR sensors monitors quality in real time, catching problems before they become scrap.

Aerospace and energy equipment

enterprise

Target: Manufacturers of turbine components and high-temperature parts using nickel superalloys

If you are an aerospace or energy equipment manufacturer struggling with crack defects when 3D-printing nickel superalloy parts via powder bed fusion — CUSTODIAN developed application-specific beam shapes validated for exactly this material class. Hot cracking in nickel superalloys is a major barrier to adopting laser-based additive manufacturing for critical components. The project's methodology designs the beam shape based on metallurgical studies and multiphysics simulation for each specific alloy.

Laser equipment and photonics

mid-size

Target: Laser system integrators and beam delivery OEMs

If you are a laser equipment manufacturer looking to offer smarter beam-shaping capabilities to your industrial customers — CUSTODIAN developed a compact Multi Plane Light Conversion (MPLC) technology that is robust and dynamic enough for production environments. The FPGA-based inline control architecture enables real-time beam shape adjustment, which you could integrate into your existing laser platforms. The consortium includes 5 SMEs and 5 industrial partners who validated the technology across multiple processes.

Frequently asked

Quick answers

What would it cost to implement this beam-shaping technology in our production line?

The project data does not include specific pricing or cost-per-unit figures. The technology involves a compact MPLC beam shaping module plus a SWIR/MWIR sensor-based control system with FPGA architecture. Contact the consortium to discuss integration costs for your specific laser setup and production volume.

Can this scale to high-volume industrial production?

The project explicitly targeted deployment in relevant industrial environments, with application scenarios in automotive exhaust welding and aerospace/energy additive manufacturing. The closed-loop inline control system was designed for production-grade operation with real-time monitoring and dynamic beam adjustment. The consortium of 10 partners across 5 countries included 5 industrial companies validating the approach.

What is the IP situation — can we license this technology?

CUSTODIAN was funded as an RIA (Research and Innovation Action) with 10 consortium partners. IP ownership typically follows Horizon 2020 rules where results belong to the partner that generated them. Contact the coordinator ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE in Spain to discuss licensing terms for the MPLC beam shaping or the control system components.

Which metals and processes has this actually been tested on?

Based on the project objectives, the technology was specifically applied to laser beam welding of austenitic steel (for automotive exhaust systems) and laser-based powder bed fusion of nickel superalloys (for energy and aeronautical sectors). The methodology was designed to be extensible to other laser processes like laser metal deposition, laser tempering, and laser softening.

How does the real-time quality control system work?

The project developed a closed-loop inline control system using uncooled SWIR/MWIR sensors paired with an FPGA architecture. This monitors the beam shape in real time and ensures it maintains the required spatial energy distribution during production. The system was designed to be both dynamic and robust enough for industrial use.

Is this ready to deploy today, or still in development?

The project ran from December 2018 to August 2022 and is now closed. It was a Research and Innovation Action, meaning the technology reached demonstration level but may require further engineering for full commercial deployment. The methodology was protocolized for extension to additional processes and materials.

Does this work with our existing laser equipment?

The MPLC beam shaping technology was designed to be compact and robust for integration into industrial laser setups. However, specific compatibility depends on your laser type and configuration. Based on available project data, the system was validated for laser beam welding and powder bed fusion — contact the consortium to assess fit with your equipment.

Consortium

Who built it

The CUSTODIAN consortium is well-balanced for industrial uptake: 10 partners across 5 European countries (Austria, Germany, Spain, France, Italy) with a 50/50 split between industry and research. Half the consortium are SMEs, which signals practical commercialization intent rather than purely academic work. The coordinator is a Spanish metallurgical research association (ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE), backed by 2 universities and 2 research organizations providing deep materials science expertise. The presence of 5 industrial partners means the technology was shaped by real manufacturing needs, not just lab curiosity — making it more likely to translate into usable products.

ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTECoordinator · ES
TECHNISCHE UNIVERSITAET WIENparticipant · AT
INSTITUTO TECNOLOGICO METALMECANICO, MUEBLE, MADERA, EMBALAJE Y AFINES-AIDIMMEparticipant · ES
NEW INFRARED TECHNOLOGIES SLparticipant · ES
SOUTHERN EUROPEAN CLUSTER IN PHOTONICS & OPTICS ASSOCIACIONparticipant · ES
POLITECNICO DI MILANOparticipant · IT
PRECITEC GMBH & CO KGparticipant · DE
MARELLI EUROPE SPAparticipant · IT

How to reach the team

ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE (Spain) — metallurgical research association coordinating the project. SciTransfer can facilitate an introduction.

Order a report on this consortium See ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE profile →

Next steps

Talk to the team behind this work.

Want to explore how custom beam shaping could reduce cracking defects in your laser manufacturing? SciTransfer can connect you directly with the CUSTODIAN team and help evaluate fit for your specific application.

Order a report on this topic More in Manufacturing & Industry 4.0