BOOST3DMETAL

Additive Manufacturing (AM) is replacing current production methods as it allows complex geometry parts manufacture for different industries, offering potential benefits in terms of weight, functionality, lead time and manufacturability. The obtained components need however to go through a number of postprocessing steps to guarantee final requirements fulfilment, for example in terms of corrosion protection. This postprocessing, which is often not considered when designing the AM process, has a significant impact on the final cost (apx. 20%), thus preventing a higher market penetration of AM. The BOOST3DMETAL project aims to boost metal AM and specifically Powder-Bed-Fusion (PBF) technology through the development and validation of: 1) design, manufacturing, and post-processing guides and assessment tools to allow producing optimised 3D geometry components made with innovative light alloys, which meet the Transport sector requirements; and 2) customised surface treatments able to treat non-homogeneous and complex AM surfaces in a synchronous way. The project and consortium cover the entire AM manufacturing process chain and the contribution of each partner is described below:

• Fraunhofer IAPT enables sustainable innovations in Additive Manufacturing. It adopts a holistic view, considering all aspects of the AM process chain from end to end. The institute will develop guidelines and a tool for the design and fabrication of AM parts, integrating post-processing considerations from the start.
• OPTIMUS 3D will contribute to the project with its capacities and knowledge in AM parts design and manufacturing. Additionally, OPTIMUS3D will provide the perspective and the industrial focus of a company fully focused on AM parts design and manufacturing and will validate the guidelines developed by Fraunhofer IAPT.
• DigitalTwin Technology will develop an advanced image software based on finite element analysis for surface quality assessment.
• Kripton will develop special chemical products adapted for the surface treatments of AM parts.
• ELHCO is the Project Coordinator and will be in charge of validating customised surface treatments for AM-made light alloys parts.

CIDETEC’S role in the project:

CIDETEC Surface Engineering, as a reference centre in surface treatments, with extensive experience in electrochemical technologies, is subcontracted by the three Spanish partners during the whole project. CIDETEC will support ELHCO, KRIPTON and OPTIMUS 3D on test definition, development of the surface treatments, and will actively participate in the surface characterization tasks throughout the project using its advanced characterization equipment. CIDETEC will also provide its pilot lines for the upscaling of the developed new processes and its validation. CIDETEC will also provide its pilot lines for the upscaling of the developed new processes and its validation.