MANUELA · Project

Complete Metal 3D Printing Pilot Line Ready for Industrial Production

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Imagine you want to 3D-print metal parts instead of machining them from a block — it could save material and let you make shapes that are impossible to cut. The problem is that metal 3D printing today involves too many disconnected steps: designing, printing, heat-treating, quality checking, each done by different specialists in different places. MANUELA built a full production line that connects all these steps — from design software through printing to automated robot handling and quality checks — so a manufacturer can run the whole process under one roof. Think of it like going from a bunch of separate craft workshops to one streamlined factory floor.

By the numbers

consortium partners across full AM value chain

countries represented in the consortium

industry partners involved

62%

industry ratio in consortium

total project deliverables completed

validated application sectors (automotive, aerospace, energy, medical)

The business problem

What needed solving

Metal 3D printing promises lighter, stronger, more complex parts — but today the production steps are fragmented across different specialists and locations, with no reliable way to monitor quality during printing or automate the handling between steps. This makes metal AM too slow, too expensive, and too risky for most manufacturers to adopt at production scale.

The solution

What was built

MANUELA delivered a complete open-access metal AM pilot line integrating laser and electron beam 3D printing with automated robot-based part handling, in-line machine-learning quality monitoring, optimized material microstructure processes, and design-for-AM simulation tools — all validated with industrial test components across 35 deliverables.

Audience

Who needs this

Aerospace component manufacturers needing complex lightweight metal partsAutomotive OEMs and tier-1 suppliers producing low-volume specialty componentsMedical device companies making custom implants or surgical instrumentsEnergy sector manufacturers producing turbine blades or heat exchangersContract manufacturers looking to add metal AM as a production capability

Business applications

Who can put this to work

Aerospace

enterprise

Target: Aerospace component manufacturers and MRO providers

If you are an aerospace parts manufacturer dealing with long lead times and expensive tooling for low-volume complex components — this project developed a complete metal 3D printing pilot line with automated quality monitoring and post-processing. The line was validated for aerospace use cases and integrates 26 partners' expertise across the full production chain, from design optimization to final part qualification.

Automotive

mid-size

Target: Automotive OEMs and tier-1 suppliers producing performance or prototype parts

If you are an automotive supplier struggling with the cost of small-batch production runs for specialized metal components — this project built an open-access pilot line covering laser and electron beam metal printing with automated robot handling and in-line quality control. The consortium includes 16 industry partners who validated the line for automotive test components with optimized microstructure and geometrical tolerance.

Medical Devices

any

Target: Manufacturers of implants, surgical instruments, or custom prosthetics

If you are a medical device manufacturer needing patient-specific metal implants but lacking in-house additive manufacturing capability — this project deployed an open-access facility with material qualification processes and machine-learning-based quality monitoring. The pilot line covers the full sequence from design for AM through post-processing, validated across 35 deliverables including automated post-processing supply chains.

Frequently asked

Quick answers

What would it cost to access this pilot line or license the technology?

The project established an open-access pilot line facility with a dedicated exploitation plan for sustainability beyond the project end (March 2023). Specific pricing is not published in the project data. Contact the coordinator at Chalmers University of Technology (Sweden) to discuss access terms and licensing.

Can this handle industrial-scale production, not just lab samples?

Yes — this was specifically an Innovation Action (IA) focused on deploying a pilot line for industrial AM production. The consortium includes 16 industry partners (62% of the 26-member consortium) and the line integrates automated robot handling of multiple 3D printers plus automated post-processing, designed for production-level throughput.

What about IP — can I use these processes in my own factory?

The project involved 26 partners across 9 countries, so IP is shared among consortium members. The stated goal was an open-access facility, suggesting licensing or access agreements are available. Specific IP terms should be discussed directly with Chalmers or the relevant technology provider in the consortium.

Which metal printing technologies does this cover?

The pilot line supports two major technologies: LPBF (Laser Powder Bed Fusion) and EBM (Electron Beam Melting). Both were instrumented with process quality control monitoring and adapted for increased reliability and speed. Material microstructure was optimized for both processes.

How does quality control work in this system?

The pilot line integrates in-line process quality monitoring using machine learning, meaning defects can be caught during printing rather than after. This is combined with automated post-AM handling by robots, reducing human exposure to metal powders and increasing consistency across production runs.

Is this compliant with industry standards for aerospace or medical parts?

The project specifically addressed material qualification for AM and standardization as key focus areas. Test components were manufactured and assessed for geometrical tolerance and surface finish. However, specific certifications (AS9100, ISO 13485) should be verified with the consortium partners directly.

How long would it take to integrate this into our existing production?

The project ran from October 2018 to March 2023, producing 35 deliverables including validated processes and an automated supply chain. Since the pilot line is already deployed and operational, access could be arranged relatively quickly. Integrating the technology into your own facility would depend on your existing infrastructure and the specific AM process chosen.

Consortium

Who built it

This is a heavyweight industrial consortium — 26 partners across 9 countries with a 62% industry ratio, which is unusually high for EU projects and signals strong commercial intent. The consortium covers the entire metal AM value chain: material and powder suppliers, AM machine manufacturers, quality monitoring systems, software providers, automation specialists, and post-processing equipment makers, plus 4 universities and 4 research institutes providing the scientific backbone. Coordinated by Chalmers University of Technology in Sweden, a leading AM research institution, the project includes 4 SMEs bringing agility alongside the larger industrial players. For a business looking to adopt metal AM, this consortium essentially represents a one-stop shop of qualified suppliers and technology providers across Europe.

CHALMERS TEKNISKA HOGSKOLA ABCoordinator · SE
EIDGENOSSISCHES INSTITUT FUR METROLOGIE METASparticipant · CH
RISE IVF ABparticipant · SE
ABB ABparticipant · SE
HITACHI ENERGY SWEDEN ABparticipant · SE
FRIEDRICH-ALEXANDER-UNIVERSITAET ERLANGEN-NUERNBERGparticipant · DE
CSEM CENTRE SUISSE D'ELECTRONIQUE ET DE MICROTECHNIQUE SA - RECHERCHE ET DEVELOPPEMENTparticipant · CH
OSAI AUTOMATION SYSTEM SPA SOCIETA' BENEFITparticipant · IT
RISE RESEARCH INSTITUTES OF SWEDEN ABparticipant · SE
ENEL GREEN POWER SPAparticipant · IT
ENEL PRODUZIONE SPAparticipant · IT
AMIRES THE BUSINESS INNOVATION MANAGEMENT INSTITUTE ZUparticipant · CZ
POLITECNICO DI TORINOparticipant · IT
SIEMENS ENERGY ABparticipant · SE
STIFTELSEN CHALMERS INDUSTRITEKNIKparticipant · SE
AMIRES SROparticipant · CZ
CARDIFF UNIVERSITYparticipant · UK

How to reach the team

Chalmers University of Technology (Sweden) — reach out to the AM research group for pilot line access and partnership inquiries

Order a report on this consortium See CHALMERS TEKNISKA HOGSKOLA AB profile →

Next steps

Talk to the team behind this work.

Want to connect with the MANUELA consortium for pilot line access or technology licensing? SciTransfer can arrange an introduction to the right partner for your specific application.

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