Additive Manufacturing Collaborations

More on how Granta supports Additive Manufacturing 

Part Specific Process Optimization in SLM - PASSPORT

Type: Active Collaborative Project funded by The European Commission, H2020 CleanSky2

Website: https://cordis.europa.eu/project/rcn/93141_en.html

Partners: TWI Ltd

As the European AM industry and design optimisation applications are growing, lead time and financial costs associated with optimising process parameters to ensure high-quality AlSi10Mg parts with complex geometry is a significant barrier to widespread adoption. PASSPORT seeks to remove this barrier and advance the state-of-the-art through the delivery of an ambitious experimental, analytical and software development programme.

PASSPORT will: (1) Undertake a detailed characterisation of AlSi10Mg SLM parts with a unique laboratory setup; (2)Employ advanced process simulations to understand and quantify the relationship between different scan strategies and part attributes; (3)Develop state-of-the-art, optimised process parameters that vary with local part topology and geometry characteristics to ensure homogeneous mechanical properties, high density and a smooth build surface; (4)Produce a bespoke, stand-alone process parameter selection software solution for AlSi10Mg SLM parts that can communicate with multiple vendors’ SLM machines; (5)Improve the time-to-market for SLM parts by removing significant cost and time-intensive burdens associated with optimising SLM builds. Granta Design will support the process parameter selection solution which is underpinned by GRANTA MI for management of physical and virtual characterization data and information.


A Net-Shape, High-Productivity Fabrication Route that Utilises Low-Cost Tools to Produce High-Complexity Parts – NIFTY

Type: Active Collaborative Project funded by InnovateUK

Partners: Maher, Replicast, The Manufacturing Technology Centre

A novel hot-isostatic pressing (HIP) process route is developed in NIFTY to enable net-shape, high-integrity components to be produced from high-performance materials. An innovative manufacturing route is developed to produce high-precision, low-cost tools, allowing the HIP process to produce complex-shape parts at lower-cost and higher throughput. An advanced powder-handling system is developed to ensure minimal contamination to the processed powders. Key innovations include a new route to produce complex-shaped components using HIP, a novel powder handling system to ensure high-purity components and a digital process selection tool.

Granta Design is developing the digital process selection tool, to assess the viability of the process for a selected component against competing technologies.


Digital Reconfigurable Additive Manufacturing Facilities for Aerospace – DRAMA

Type: Active Collaborative Project funded by InnovateUK & The Aerospace Technology Institute

Partners:The Manufacturing Technology Centre, Renishaw, Autodesk, ATS, Midlands Aerospace Alliance, NPL, University of Birmingham

DRAMA will establish leading additive manufacturing ‘test bed’ facilities for the aerospace industry and its supply chain at the National Centre for Additive Manufacturing (based at the MTC in Coventry) and the Renishaw AM Solution Centre in Stone. The project will showcase the use of digital technologies to drive productivity and reliability in AM, leading to increased adoption of AM technologies by the aerospace sector and, in the long term, other industrial sectors. It will also deliver the world’s first digitally-twinned reconfigurable AM facility and establish the UK as a global leader in additive manufacturing technology. The project, part of the ATI programme, has received a grant of £11.2 million through the UK’s Industrial Strategy Challenge Fund.

Granta Design is providing the platform for the digital infrastructure of the AM facilities, implementing a robust materials information management system, able to capture the relevant information from the entire AM process chain (data and metadata capture from manufacturing machines & testing, powder qualification and use, inspection, material and process modelling). Granta is developing the digital AM knowledgebase repository and software tools for the facilities’ digital twin model.


Distortion Reduction and Elimination for Additive Manufacturing - DREAM

Type: Active Collaborative Project funded by InnovateUK

Partners: TWI, Materialise, Nquiringminds

The DREAM project will address the challenge of distortion in Selective Laser Melting (SLM) manufactured components through a multidisciplinary digital approach, coupling real-time data acquisition, advanced modelling, cloud-based computing, and adaptive machine process parameter control to achieve zero-distortion builds, independent of powder supplier and machine manufacturer. The software, hardware, and cloud-based solution will allow internet-enabled machines and systems to identify distortion during the build process and make real-time decisions and forecasts about process parameter controls to mitigate and control distortion during the build process. The outcomes will result in cost reduction, higher material utilisation, improved quality assurance, and reduced design cycle times in the SLM process chain.

Granta Design is developing the data exchange strategy with machine and modelling tools for the transmission of process parameters and distortion correction.


AMAZEAMAZE (a European Union FP7 project)

Type: Completed Collaborative Project funded by the European Commission, FP7

Website: www.amazeproject.eu

Partners: Airbus Defense and Space, Avio, AvioProp, BAE Systems, BCT, Bombardier, Concept Laser, Cranfield University, EPA Lausanne, ESA, ESI, FAU Erlangen-Nürnberg, Fraunhofer, Granta Design, Irepa Laser, Manchester University, Monash University, MTC, Norsk Titanium, Politecnico di Torino, Renishaw, Swansea University, Tecnalia, Thales Alenia Space, Trumpf, UKAEA, University of Birmingham, Volvo

The goal of the Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products (AMAZE) project is to rapidly produce large defect-free additively-manufactured (AM) metallic components up to 2m in size, ideally with close to zero waste, for use in the following high-tech sectors namely: aeronautics, space, automotive, nuclear fusion and tooling. The team is the largest and most ambitious ever assembled on this topic. Granta is providing an overarching materials information management system for the consortium as a single go-to source of knowledge on materials, processes and properties for process refinement and coordination. We are also involved in data provision for simulation activities.

READ THE FULL CASE STUDY


Manudirect project (a European Union FP7 project)

Type: Completed Collaborative Project

A European Nanotechnologies Project that aimed to provide industry with a new platform for manufacturing nano-materials and structures using a high productivity, high resolution, direct, one step laser sintering process. Granta managed materials data relating to the project and to model the behavior of micro-managed materials. Granta acknowledges funding from this project that helped with initial development work on the Hybrid Synthesizer product. Manudirect is EU project contract no NMP2-CT-2006-026467.


Nanomicro logoNanoMicro (a European Union FP7 project)

Type: Completed Collaborative Project

Partners: Universidad Politécnica de Cartagena, MBN nanomaterialia, microLS, INOV, Manudirect srl, Granta Design, University of Cambridge, MATRES s.r.c.l., Laser Zentrum Hannover, Datalogic SpA, Telemaq

The NanoMicro project provided the manufacturing industry with an entirely nano-micro-manufacturing platform, by way of a new micron-scale resolution and an innovative direct parallel-deposition process. The process was be able to deliver a layer-wise manufacturing approach using highly focalized powder/heat fluxes. Granta undertook materials design and selection activities for the project partners, balancing ecological materials selection criteria with product cost. Granta developed additional functionality for the Hybrid Synthesizer in CES Selector to support the assessment of novel hybrid materials for the manufacture of high performance micro parts.

Press release 


Step-up logoStep-Up (a European Union FP7 project)

Type: Completed Collaborative Project

Website: European Commission Project Page

Partners: BMW, MBN Nanomaterialia S.p.A., MATRES s.c.r.l.,University of Cambridge, Granta Design

"Step Up in Polymer Based Rapid Manufacturing Processes" provided a wide variety of innovative Selective Laser Sintering systems to enable the creation of "final components" through the employment of innovative nano-charged polymers. A mechano-chemical approach was used for the development of these innovative nanocomposites. Granta undertook  materials eco-design and selection activities, collaborating on SLS materials data modeling, as well as providing materials data handling for the project partners. Granta provided expertise on the simulation of polymer hybrid materials for Selective Laser Sintering, enabling a broadening of the materials palette available for this manufacturing route and building knowledge on available SLS polymers.