AM technologies are layer-based and tool-free manufacturing processes, which represent a direct interface between the virtual product development and the real-world production of final products. As fundamental part of the “industrial internet of things” (IIoT), AM is considered to be a flexible solution for a demand-driven supply of individualized products. Especially the LBM technology is considered predestined for industrial production due to its intrinsic characteristic of processing metal additively. Moreover, physical properties similar to the ones of conventionally manufactured parts are achievable. LBM enables the flexible and fast production of near net-shape metal parts with up to 100 % density. MOnACO aims at the design optimization and successful additive manufacturing (AM) of a large-scale (diameter of 1 m) aircraft engine’s component via laser beam melting (LBM) technology. The project contains the development of new design guidelines and tools for the redesign of large-scale LBM structures and the implementation of the complete AM process chain. In accordance to the topic description (JTI-CS2-2018-CfP08-ENG-01-32 ), the approach splits into three main tasks: Component analysis, design and optimization; additive manufacturing optimization and validation; component design experimental investigation.

The LASIMM project aim is to develop a large scale flexible hybrid additive/subtractive machine based on a modular architecture which is easily scalable. The machine will feature capabilities for additive manufacture, machining, cold-work, metrology and inspection that will provide the optimum solution for the hybrid manufacturing of large engineering parts of high integrity, with cost benefits of more than 50% compared to conventional machining processes. For large scale engineering structures material needs to be deposited at a relatively high rate with exceptional properties and excellent integrity. To ensure this the machine is based on wire + arc additive manufacture for the additive process. A unique feature of the machine will be the capability for parallel manufacturing featuring either multiple deposition heads or concurrent addition and subtraction processes. To facilitate parallel manufacturing the machine architecture is based on robotics. To ensure that the surface finish and accuracy needed for engineering components is obtained for the subtractive step a parallel kinematic motion robot is employed. This robot is also used for application of cold work by rolling between passes. This ensures that material properties can be better than those of forged material. A key part of this project is the development of ICT infrastructure and toolboxes needed to programme and run the machine. The implementation of parallel manufacturing is extremely challenging from a software perspective and this will be a major activity within the project. To deliver this extremely demanding and ambitious project a well-balanced expert team has been brought together. There are ten partners comprising six companies, two Universities and two research institutes. Two of the companies are SMEs and there are three end users from the renewable energy, construction and aerospace sectors. The consortium also features the whole of the supply chain needed to produce such a machine.

Proposal abstract The FOCUS project will build upon the fundament of five existing FoF Clusters, Zero Defect Manufacturing (4ZDM), Robotics, Clean factory, Precision Micro Production Technologies (High Micro) and Maintenance and support. They will work toward the following four objectives. 1. Provide pro-active support to the projects in the participating clusters to disseminate the project’s tangible outcomes to raise the awareness and thus increasing on a short term the industrial exploitation and take-up (“As-is”). 2. Elaborate on the common ground of the clusters to establish a European state-of-the-art and world-wide technology watch to inform the European manufacturing industry constantly while also formulating (with support from cluster specific top-ranked experts) the future FoF priorities based upon jointly identified business trends and market prospects (“As-is”). 3. Deliver a proven model and associated methodology for effective cluster creation, execution and monitoring based upon the experience of the five participating clusters in FOCUS. This methodology will considerably ease the process of creating cluster thus maximizing the possibilities of increasing the impact of ‘exploiting’ cross-project synergies (“To-be”). 4. Deliver a model and associated methodology to ensure industrial exploitation and industrial take-up for future projects including guidelines for all stakeholders including the European Commission, project initiators and partners (“To-be”). The final outcome of Focus will be: • FOCUS model for clustering and industrial exploitation known at relevant stakeholders • Methodology for clustering • Methodology for industrial exploitation & take-up • Lesson learnt from the existing clusters

Individualised production is an emerging trend in manufacturing. Laser-based Additive Manufacturing (LBAM) fits well with this trend, due to its capability of transforming digital designs directly into physical products. LBAM is not yet competitive for a widespread industrial adoption: post-processing operations are necessary and they are not currently integrated, human intervention is needed to overcome technology gaps, and a poor integration with production planning systems hinders process traceability and resource optimisation. HyProCell proposes the combination of available cutting-edge LBAM machines and ICT innovations within an integrated multiprocess production cell, which will include at least LBAM and subtractive manufacturing machine/s, in order to ensure a fully finished product from the incoming raw material. The general objective of HyProCell is to implement and validate this concept in real settings, manufacturing real parts and measuring obtained benefits. HyProCell is expected to produce a sound impact on all the stakeholders of LBAM-related industry: - Making feasible a demand-driven LBAM production process supported on fast manufacturing procedure development capacities; - Creating highly automated and integrated multiprocess production cells, thus reducing dramatically downtime. - Enabling the rapid reconfiguration of the production cells, for scalability and/or new product demands, thanks to their modular architecture. - Fully enabling end-users to address new production trends. Relevant technological impacts are expected on hardware and software levels. A well-balanced consortium representing from machine manufacturers and end-users to Photonics experts, industrial automation specialist, ICT for smart manufacturing providers and technical services assures to meet project goals. Heavy involvement of SMEs (50% of the budget) guarantees an outstanding innovation push.

In nearly every sector of industrial manufacturing polishing techniques are used. But often manual polishing is the only option because the tasks are too complex to be automated. Therefore in SYMPLEXITY Symbiotic Human-Robot Solutions for Complex Surface Finishing Operations will be developed. The main SYMPLEXITY Objectives are SO 1 – Accurate and cognitive industrial robot systems enabling safe human-robot collaboration for surface finishing operations SO 2 – Easy to use interfaces for planning, control and re-planning of shared finishing tasks SO 3 – Collaboration oriented process technology for abrasive finishing, laser and fluid jet polishing SO 4 – Integrated and autonomous sensing system for objective identification of surface properties SO 5 – Introduction of developed collaborative finishing solutions into manufacturing industry In SO5 the results of the first 4 objectives will be combined to 3 demonstrator human-robot collaboration cells, one for each of the investigated process technologies. The 3 demonstrator cells will be tested in operational environment at 3 end-users. SYMPLEXITY is the consistent continuation of 3 recent EU projects that achieved TRL 4-5: COMET – Plug-and-produce COmponents and METhods for adaptive control of industrial robots SAPHARI – Safe and Autonomous Physical Human-Aware Robot Interaction poliMATIC – Polishing processes and tools development SYMPLEXITY will bring together the results and key partners of these 3 projects to achieve TRL7 and thereby support the European Industry to win the competition in the global market with higher quality, efficient manufacturing and economic production, based on human robot collaboration for polishing complex shaped metallic surfaces. Relevant branches are tool making, medical engineering, aeronautics and automotive industry. Case studies show, that for many applications todays >90% of manual work can be converted in 80 % of robotic work under human control and 20 % of manual work.