Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products

Third Party Funds Group - Sub project

Overall project details

Overall project: Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products

Project Details

Project leader:
Prof. Dr.-Ing. Carolin Körner

Contributing FAU Organisations:
Lehrstuhl für Werkstoffwissenschaften (Werkstoffkunde und Technologie der Metalle)

Funding source: EU - 7. RP / Cooperation / Verbundprojekt (CP)
Acronym: AMAZE
Start date: 01/01/2013
End date: 30/06/2017

Research Fields

Modelling and Simulation
Lehrstuhl für Werkstoffwissenschaften (Werkstoffkunde und Technologie der Metalle)
Additive Manufacturing
Lehrstuhl für Werkstoffwissenschaften (Werkstoffkunde und Technologie der Metalle)

Abstract (technical / expert description):

The overarching goal of AMAZE is to rapidly produce large defect-free additively-manufactured (AM) metallic components up to 2 metres in size, ideally with close to zero waste, for use in the following high-tech sectors namely: aeronautics, space, automotive, nuclear fusion and tooling.

Four pilot-scale industrial AM factories will be established and enhanced, thereby giving EU manufacturers and end-users a world-dominant position with respect to AM production of high-value metallic parts, by 2016. A further aim is to achieve 50% cost reduction for finished parts, compared to traditional processing.

The project will design, demonstrate and deliver a modular streamlined work-flow at factory level, offering maximum processing flexibility during AM, a major reduction in non-added-value delays, as well as a 50% reduction in shop-floor space compared with conventional factories.

AMAZE will dramatically increase the commercial use of adaptronics, in-situ sensing, process feedback, novel post-processing and clean-rooms in AM, so that (i) overall quality levels are improved, (ii) dimensional accuracy is increased by 25% (iii) build rates are increased by a factor of 10, and (iv) industrial scrap rates are slashed to <5%.

Scientifically, the critical links between alloy composition, powder/wire production, additive processing, microstructural evolution, defect formation and the final properties of metallic AM parts will be examined and understood. This knowledge will be used to validate multi-level process models that can predict AM processes, part quality and performance.

In order to turn additive manufacturing into a mainstream industrial process, a sharp focus will also be drawn on pre-normative work, standardisation and certification, in collaboration with ISO, ASTM and ECSS.

The team comprises 31 partners: 21 from industry, 8 from academia and 2 from intergovernmental agencies. This represent the largest and most ambitious team ever assembled on this topic.

External Partners

European Space Agency (ESA)
Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
École Polytechnique Fédérale de Lausanne (EPFL)
TRUMPF Laser- und Systemtechnik GmbH
Renishaw plc
Tecnalia Research & Innovation Foundation
Avioprop S.r.l.
The Manufactoring Technology Centre Limited (MTC)
Granta Design Ltd.
Politecnico di Torino
Avio S.p.A
Concept Laser GmbH
University of Birmingham
Cranfield University
UK Atomic Energy Authority
Swansea University
Thales Alenia Space
EADS Deutschland
ESI Group
University of Manchester
BCT Steuerungs- und DV-Systeme GmbH
BAE Systems plc
Monash University
Norsk Titanium (NTi)
AB Volvo

Last updated on 2018-22-11 at 19:01