Additive Manufacturing (AM) embraces a terrific innovation in the field of complex shape part manufacturing. The next generation of machines and systems for AM will be based on cross-sectorial process technologies easily transferrable to very different applications. Particularly, this research area focuses on the metal based additive manufacturing complemented by a number of subtractive technologies; operating by persistently monitoring and adapting the deposition or subtraction processes, by relying upon an online closed loop process monitoring and control platform.
Systems and Technologies for Additive Manufacturing - ISTePS
Additive Manufacturing
Metal Additive Manufacturing (AM) is forging a new era of technologies and shaping a new engineering approach to create innovative product solutions. The ARM Lab embraces this new fabrication paradigm, supporting the industry to unleash the disruptive potential of freeform fabrication, conducting research activities on:
- Definition and implementation of optimised application-driven product/process design rules.
- Optimisation of process parameters and post-processing strategies for advanced materials (e.g., Ti-based alloys, Ni-based superalloys, High Entropy Alloys) and heterogeneous structures (e.g., Functionally Graded Materials).
- Process-structure-property relationship engineering for laser-based Direct Energy Deposition and Powder Bed Fusion.
- Process monitoring and control.
- AM component assessment and characterization under relevant industrial conditions
Ultrashort pulsed laser processing
Femtosecond lasers are being explored for their potential in precise material removal and modification with minimal thermal impact. This includes the ablation of micro- and nanostructures on metal components to enhance surface properties, such as the functionalization of titanium prostheses to prevent infections and promote osseointegration. Ultrashort pulses also enable advanced glass processing; techniques like Selective Laser Etching (SLE) and laser welding facilitate the creation of microfluidic devices by forming channels within glass slides, essential for biomedical lab-on-chip applications.
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Hybrid and multi-technology advanced processes
The ARM Lab鈥檚 home-built technologies integrate femtosecond laser processing and Direct Atomic Layer Processing (DALP) on a single machine, creating a world-first platform for microdevice manufacturing. These technologies enable additive work at 脜ngstr枚m resolution with thin-film deposition, and submicron precision for multiphoton polymerization. Additionally, USP laser technology supports work on any material through heatless welding and subtractive manufacturing. A special emphasis is placed on glass applications, including glass-to-glass and glass-to-metal welding, as well as Selective Laser Etching (SLE) for microfluidics and lab-on-chip production.
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Cold spray
ARM Lab studies and optimizes the Supersonic Cold Spray process and develops novel transportable and compact solutions for processing high strength metal alloys. The developed solutions exceed the performance and applicability of commercial Cold Spray systems with several different materials.
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- Metal material process design (mostly: high carbon content steel, Ti64, Aluminum alloys)
- Hybrid process implementation based on deposition and subtraction of material
- Redundant Machines and Robotic solutions for AM
- Process control and adaptation based on a closed loop monitoring system
- Mechatronic equipment design for multi-material deposition (i.e. nozzle, primary and secondary deposition systems, vacuum systems, auxiliary gas ejection, gas-powder mix chamber)
- Aerospace Industry
- Mold and die industry
- Oil and gas industry
- Endhoprostetics and exoprosthetics medtech industry