Benefits & impacts

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Benefits

Compared to the existing procedures in laser-based additive manufacturing, the 4 main impacts of the MAESTRO project will be:
  • 1- To improve the productivity by 30%
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    Compared to the existing laser-based Additive Manufacturing procedures, MAESTRO is owing to:
    • (i) hybrid monitoring which will optimize the whole process by focusing DMLS only on complex parts that require high accuracy and precision; whereas the rest of the operation on rougher parts will be achieved using MIM, thereby saving time and speed of processing,
    • (ii) an adaptive process control that will minimize the failure rate by providing in-line thermal and mechanical monitoring throughout the process chain.
  • 2 – To reduce the cost by 30%
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    Compared to the existing procedures, MAESTRO will develop:
    • (i) adaptive process control that will limit the scrap rate, thereby increasing the production efficiency leading to savings in raw material consumption and hence the costs,
    • (ii) a single pre-process software that reduces the time to market by merging all numerical pre-processing steps into a unique one.
  • 3 – To produce high quality
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    MAESTRO will produce complex metallic objects with high accuracy (± 1.5 µm) and precision (≤ ± 0.1%) while maintaining the cost and productivity benefits, leading towards zero defect production by:
    • (i) developing an adaptive process control that will minimize the fault rate and
    • (ii) system level integration ensuring pre and post-processing enhancement and thus improving the design to piece reliability.
  • 4 – To integrate all modules
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    The project will integrate all modules in a platform to validate MAESTRO’s technology robustness and reproducibility in R&D developments.

    Based on the manufacturing assessment of a critical number of industrial demonstrators (four from consortium end-users, three from external companies), MAESTRO will reinforce the industrial leadership in the consortium, as well as companies that will benefit from the project’s results.

Impacts

In order to maximize its impact, MAESTRO aims at organizing dissemination actions targeting the industrial and research communities.

In particular, MAESTRO will:

  • animate working groups to evaluate the platform capabilities and specify its potential for future use after the end of the project: markets, business models of the platform, implementation of “daughter” factories, etc,
  • demonstrate “live” the platform capabilities,
  • organize a contest event on products to be manufactured through the platform: companies will be invited to propose case studies for future high impact applications. read more…The proposals will be evaluated (vs. economical, technical and societal criteria) and ranked by the project partners.
    For each of the three best proposals, the fabrication process will be assessed with respect to industrialisation requirements, i.e. throughput time, process parameter control, yield, cost.
    Free AM prototyping of the products will be proposed to the winner of the contest.