The BOREALIS project has been an opportunity to create much more value than the technical solution itself.

This value today is represented by the different initiatives that the Consortium has created and that are on going. 

The further value of Borealis project then represented by the developments and further investments that the partners of Borealis have been sustained. 

 

 

 

 

 

 

Exploitable Results

  • The Borealis machine: Borealis system is composed by a redundant machine architecture whose design consisting of a deposition head mounted on a large portal enables the reaching of working cubes ranging from 150x150 mm (15° tilt in two directions) up to 4000x1500x750 mm. The machine presents 7 Degrees of Freedom DoF (4 on the deposition head and three on the machine portal). The portal is equipped with a hybrid technology optical chain: a 3D laser scanner designed with 2 tilting DoFs and one linear adaptive collimator are connected to a beam combiner which supplied by two laser sources, respectively covering continuous power and pulsed power sources. The scanner integrates a closed loop monitoring system composed by a hyperspectral camera on-camera processing solution. To provide more flexibility in terms of complexity and shape of the parts to be produced, 2 more DoFs are provided by a commercial roto-tilt table which will be part of the integrated machine. The integration process concerns also the nesting and positioning of the vision cameras. The vision system configuration includes two fixed spot stereo cameras and a set of cameras which requires to be moved to monitor the product and process quality together with the equipment behaviour. The vision system is part of a comprehensive smart sensing system architecture embedded in each mechatronic module, capable of monitoring and continuously supporting the entire additive and subtractive manufacturing process by gathering appropriate KPI values that are delivered to the numerical controller to update the control actions.

  •  Configurable head: An innovative deposition head equipped with 4 independent nozzles for multi-material applications and a shielding gas system for controlled atmosphere. An advanced hybrid optical chain for delivering both the 3 kW CW laser source for DED process and the ultrashort pulsed laser beam for subtractive applications. A high-speed 3D scanner head customized for high power and high accuracy processes allowing innovative and improved efficiency strategies for AM, ablation and patterning. The scanner integrates a closed loop monitoring system composed by a ccd camera in the monochromatic spectral sensitivity. An innovative method to optimize shape and size of the melting pool.

  • Multi Nozzle System: A new concept of modular nozzle able to increase the efficiency of powder deposition. Each nozzle has an independent carrier and shielding gas flow to increase the process flexibility.

  • Powder feeding system: This ER is about an innovative powder feeding system that allows an independent regulation of carrier and powder flow for every nozzle that is mounted on the deposition head. It also foresees an innovative powder collecting system

  • Process control: Closed loop control of the process, comparing the actual status of the process with respect to the nominal baseline and coordinate adaptive control of nozzles and laser beam

 

 

 

 

 

Integrated Additive Manufacturing @ PoliTO

Politecnico di Torino opened the new  IAM@POLITO center, aiming to create a multidisciplinary Additive Manufacturing research platform with the aim of dealing with and overcoming the open challenges, in terms of machinesmaterials and applications, and of contributing, together with other industrial actors, in the development of new generation systems destined for final production from the Industria 4.0 viewpoint.

The expertise and collaboration of the DISAT and DIGEP research groups with IIT is an element of distinction and excellence of the IAM@PoliTo Center, which covers all the engineering activities related to material development, product and process design, process optimization, part fabrication and finishing

 

 

 

 

 

 

 

New ARM-Lab @ SUPSI

The Laboratory of Automation Robotics and Machines (ARM-Lab) @ SUPSI supports the mission of the Institute in the areas of robotic based automated production systems and reconfigurable industrial robotics, systems and industrial technologies for Additive Manufacturing and 3D printing, industrial automation and 2D/3D vision systems.

To this purpose, reconfigurable industrial robots, robotic islands and Redundant Machines for AM are designed and developed, their kinematics and dynamics are modeled,  their control infrastructure is implemented together with path and process planning design and simulation, task sequencing and dispatching. Mechatronic equipment, metal and composite material processes are designed for multi-material deposition, and hybrid processes based on deposition and subtraction of material are implemented too. Furthermore, new automation solutions which can integrate 2D/3D vision systems are developed, e.g. to measure features or recognize defects in processes, products and surfaces.

 

 

 

 

 

AM Team and Additive Tech center @ Prima Industrie

  • The Borealis machine: Borealis system is composed by a redundant machine architecture whose design consisting of a deposition head mounted on a large portal enables the reaching of working cubes ranging from 150x150 mm (15° tilt in two directions) up to 4000x1500x750 mm. The machine presents 7 Degrees of Freedom DoF (4 on the deposition head and three on the machine portal). The portal is equipped with a hybrid technology optical chain: a 3D laser scanner designed with 2 tilting DoFs and one linear adaptive collimator are connected to a beam combiner which supplied by two laser sources, respectively covering continuous power and pulsed power sources. The scanner integrates a closed loop monitoring system composed by a hyperspectral camera on-camera processing solution. To provide more flexibility in terms of complexity and shape of the parts to be produced, 2 more DoFs are provided by a commercial roto-tilt table which will be part of the integrated machine. The integration process concerns also the nesting and positioning of the vision cameras. The vision system configuration includes two fixed spot stereo cameras and a set of cameras which requires to be moved to monitor the product and process quality together with the equipment behaviour. The vision system is part of a comprehensive smart sensing system architecture embedded in each mechatronic module, capable of monitoring and continuously supporting the entire additive and subtractive manufacturing process by gathering appropriate KPI values that are delivered to the numerical controller to update the control actions.

  •  Configurable head: An innovative deposition head equipped with 4 independent nozzles for multi-material applications and a shielding gas system for controlled atmosphere. An advanced hybrid optical chain for delivering both the 3 kW CW laser source for DED process and the ultrashort pulsed laser beam for subtractive applications. A high-speed 3D scanner head customized for high power and high accuracy processes allowing innovative and improved efficiency strategies for AM, ablation and patterning. The scanner integrates a closed loop monitoring system composed by a ccd camera in the monochromatic spectral sensitivity. An innovative method to optimize shape and size of the melting pool.

  • Multi Nozzle System: A new concept of modular nozzle able to increase the efficiency of powder deposition. Each nozzle has an independent carrier and shielding gas flow to increase the process flexibility.

  • Powder feeding system: This ER is about an innovative powder feeding system that allows an independent regulation of carrier and powder flow for every nozzle that is mounted on the deposition head. It also foresees an innovative powder collecting system

  • Process control: Closed loop control of the process, comparing the actual status of the process with respect to the nominal baseline and coordinate adaptive control of nozzles and laser beam

 

 

 

 

 

First Italian and European Master in AM

The BOREALIS project gave the possibility to launch the first Italian and European Master in Additive Manufacturing, promoted by prima Industrie and Politecnico di TORINO, in cooperation with other Italian companies such as IRIS and AVIO AERO. Here, young graduated person have the opportunity to follow 2 years of courses focused on the Additive Manufacturing approach.

The objective of this programme, now arrived at the third edition, is to train young, motivated newly-graduated engineers in order to create a new generation of high-level specialists in the field of additive manufacturing.
This programme is designed to prepare future Technical Leaders, Project Managers, Industrial Operational Leaders, Mechanical Designers, Software Designers and Spare Parts Managers.
The peculiarity of these international professional profiles is to merge technical and managerial expertise for the implementation and management of Additive Manufacturing.
As a consequence, the 2nd level Specializing Master’s programme offers its participants a unique opportunity to be trained in an international environment and to gain work experience by getting involved in high-level projects. 

It offeres the possibility to develop a career in AM with specialized courses about:

  • Design for Additive Manifacturing;
  • Materials for Additive Manifacturing;
  • Technologies for Additive Manifacturing
  • Systems and ICT

Different people coming from this Master have been hired by Italian companies for the Additive Manufacturing technology and some of these Companies are also the one in the Borealis Consortium. Indeed 17 young graduated have been hired for the Borealis project and now these people will carry on further  developments in the same companies.

 

 

 

 

 

 

 

Publications and conference papers

  • Federico Mazzucato, Simona Tusacciu, Manuel Lai, Sara Biamino, Mariangela Lombardi, Anna Valente, (2017) Monitoring Approach to Evaluate the Performances of a New Deposition Nozzle Solution for DED Systems.In: TECHNOLOGIES, vol. 5 n. 2, 29-. - ISSN 2227-7080

  • Abdollah Saboori, Simona Tusacciu, Mattia Busatto, Manuel Lai, Sara Biamino, Paolo Fino, Mariangela Lombardi, (2018), Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition In: JoVe – Journal of Visual Experiments, 56966_R3_RE

  • Abdollah Saboori, Donato Gallo, Sara Biamino, Paolo Fino, Mariangela Lombardi, (2017) An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties. In: APPLIED SCIENCE, vol. 7, 883. ISSN 2076-3417 

  • Federico Mazzucato, Andrea Marchetti, Anna Valente, (2018), Analysis of the Influence of Shielding and Carrier Gases on the DED Powder Deposition Efficiency for a New Deposition Nozzle Design Solution, In: Springer International Publishing, AG 2018

  • Yu, G.Rossi, A.Braglia, G.Perrone, Development of a 300W 105/0.15 fiber pigtailed diode module for additive manufacturing applications, (2017), In: Proceedings of SPIE - The International Society for Optical Engineering SPIE High-Power Diode Laser Technology XV 2017, San Francisco (USA) Jan-Feb 2017, pp 5, pagine 1-5, ISBN: 9781510606135

  • Yu, G.Rossi, A.Braglia, G.Perrone, Artificial neural network assisted laser chip collimator assembly and impact on multi-emitter module beam parameter product, (2017), In: Proceedings of SPIE - The International Society for Optical Engineering SPIE Components and Packaging for Laser Systems III 2017, San Francisco (USA) Jan-Feb 2017, pp 7, pagine 1-7, ISBN: 9781510606111

  • Papacharalampopoulos, H. Bikas, P. Stavropoulos, “Path planning for the infill of 3D printed parts utilizing Hilbert curves”, 15th Global Conference on Sustainable Manufacturing

  • Komineas, P. Foteinopoulos, A. Papacharalampopoulos, P. Stavropoulos, “Build Time Estimation Models for Thermal Extrusion Additive Manufacturing Processes”, 15th Global Conference on Sustainable Manufacturing

  • Foteinopoulos, A. Papacharalampopoulos, P. Stavropoulos, “On Thermal Modeling of Additive Manufacturing Processes” CIRP Journal of Manufacturing Science and Technology, 2017, ISSN 1755-5817, https://doi.org/10.1016/j.cirpj.2017.09.007

  • Erica Librera, Alberta Aversa, Mandanà Moshiri, Paolo Fino, Sara Biamino, Mariangela Lombardi, Matteo Pavese, Diego Manfredi, Flaviana Calignano, Elisa Ambrosio, Massimo Lorusso (2016) Study of Single Tracks with AlSi10Mg and Composites Powders, WorldPM 2016, 9 - 13 October 2016, Hamburg, Germany

  • Alberta Aversa, Mandanà Moshiri, Simona Tusacciu, Mattia Busatto, Manuel Lai, Flaviana Calignano, Diego Manfredi, Matteo Pavese, Mariangela Lombardi (2017), A Comparison of the Laser Powder Interaction in Laser Powder Bed Fusion and Direct Energy Deposition Processes, EuroPM 2017, 1 - 5 October 2017, Milan, Italy

  • Aversa Alberta, Tusacciu Simona, Reggio Elena, Busatto Mattia, Lai Manuel, Manfredi Diego, Biamino Sara, Fino Paolo, Lombardi Mariangela. Direct Energy Deposition Of AlSi10Mg, XIV Convegno Nazionale AIMAT 2017, 12-15 Luglio 2017 Ischia Porto (NA), Italy

  • Saboori Abdollah, Biamino Sara, Lombardi Mariangela, Fino Paolo, Tusacciu Simona, Busatto Mattia, Lai Manuel (2017), Characterization of Single Track Formation from Ti-6AL-4V Alloy at Different Process Parameters by Direct Energy Deposition, EuroPM 2017, 1 - 5 October 2017, Milan, Italy

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