Innovation Highlights

HyProCell realised pilot cells to prove its automated hybrid production workflows in real settings by manufacturing real parts. Some of the key innovations are:

CAx Tools
Developed and customised different software to streamline the AM workflow in the cells. NetFabb and PowerShape Utility were used for PBF process in the SLM Pilot and PowerMill for LMD and five-axis machining. Design and Process Data is made accessible for anyone anywhere and anytime by  using Autodesk’s Cloud Solutions based on Fusion Team deployment.

CAx Tools

Automation
Developed OPC Unified Architecture Adapters and Middleware Components that enable data acquisition and process control for both additive and conventional manufacturing machines. These enable data acquisition and process control for both additive and conventional manufacturing machines in the context of a reconfigurable and standardised system architecture. Using this architecture not only the production was modularised, but also the engineering processes were decoupled, the development of each cell could be done independently and encapsulated regarding the inner functionality.


 

Manufacturing Execution System (MES)
Developed an MES that not only collects, displays and stores cell status information and order status tracking, but also acts as a dispatcher of information between the integration layer and other components of the system. The MES is fully implemented in SLM Pilot Cells.

LBAM Machine Enhancements
Added external controls to the LBAM Adira machine and made it operational as a connected module of an integrated production process. Specific novel features included a) TLM moveable chamber concept uses a modular processing head over the machine table; b) Automatic back door for robot access; c) Robot arm with dust box (including sealing elements); d) Auto de-powdering module coupled to the process chamber; and e) Process development to work with Nitrogen as inert gas when Nickel based alloy is processed.

Adapted the Hybrid LMD Hamuel machine achieving superior control capacities, including a laser line scanning system for in-process geometrical control.

BCT scanner results_LMD pilot

Robotics & Part Handling
Sourced suitable robotic arms and designed robust pallet systems capable of handling the parts in the pilots.  The systems demonstrated can handle parts with dimensions of  400x500mm and weight of 400kg. A novel dust box system and handling arm was specifically developed for SLM pilot cell.

Automation highlights

Objectives

HyProCell’s general objectives are:

  • To develop and demonstrate a new concept of multiprocess production cell.
  • To implement them at industrial level and validate them in pilot facilities.

Challenges

HyProCell tackles both technological and industrial challenges, as it aims to implement lab validated technologies in industrial facilities.

HyProCell has direct technological and industrial impacts, as well as indirect environmental and social ones.

Impact

HyProCell has direct technological and industrial impacts, as well as indirect environmental and social ones. All of them are timely considering the need to increase Europe’s competitiveness in global markets, comply with environmental policies and creation of highly skilled jobs.

Progress

HyProCell has realised pilot cells to prove its automated hybrid production workflows in real settings by manufacturing real parts.