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4D HYBRID – Novel ALL-IN-ONE machines, robots and systems for affordable, worldwide and lifetime Distributed 3D hybrid manufacturing and repair operations

4D Hybrid main objective is to develop a new concept of hybrid Additive Manufacturing (AM) based on the modular integration of compact, low cost modules including laser source, deposition head, sensors and control. 4D aims to introduce a novel multilevel hybridization concept: it is possible to combine elementary process in one hybrid module, to create with them hybrid machine tools, base for a new generation of advanced hybrid production lines. It enables unprecedented possibility to exploit the potential of AM techniques. The same certified process may be used in different places and phases of product lifecycle: for initial production, for defective parts inspection and recovery, for in situ repairing operations.

4D will demonstrate the effective application to aerospace, oil & gas and power generation equipment. The concept can be further exploited in automotive, railway, ship building with a huge potential in the global market.

The four principal breakthroughs are:

  1. A set of four elementary modules specifically designed for AM that embed the control and monitoring systems which can be integrated one to another in multiple combinations as well as integrated on new or existing concepts of machines and robots to realize different process ranging from Direct Energy Deposition (powder and wire) to ablation and cold spray.
  2. A new concept of CNC, constituting a high level sw layer which can be integrated on the top of the current commercial CNCs, and it is conceived as open to embed portion of the 4D modules control. This would concurrently boost the retrofit paradigm and the possibility to persistently innovate the 4D modules over the years.
  3. A validated process model to fully exploit the synergistic interactions among elementary processes focusing on direct metal deposition, cold spray, machining and thermal processes as well as their usage in synergy with traditional metal cutting technologies.
  4. A dedicated 4D Engineering CAD/CAE/CAM Platform, which covers the lifecycle of the reference product family where multiple processes and hybrid resources are integrated for the (re)manufacturing stage and 3D image matching technologies are integrated for the product lifecycle assessment stage

The consortium, with Prima Electro as coordinator, involves universities, research centers and businesses: 3D New Technologies, COMAU, Council for Scientific and Industrial Research, GE Aviation, Globotics Industries, International TechneGroup, IRIS, Keen Bull, Koord, Laboratory for Manufacturing Systems & Automation, MCI Group, Optomec, Politecnico Di Torino, Prima Power Laserdyne, Ramteid GmbH, Siemens, SUPSI, Technology Transfer System, University of Birmingham.

The project has received funding from the European Union's Horizon 2020 research and innovation programme and has a duration of 36 months starting 1st January 2017.

Last updated 2018-01-11 15:03:04

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