The aim of DREAM is to significantly improve the performances of laser Powder Bed Fusion (PBF) of titanium, aluminium and steel components in terms of speed, costs, material use and reliability, also using a LCA/LCC approach, whilst producing work pieces with controlled and significantly increased fatigue life, as well with higher strength-to-weight ratios. DREAM targets the development of a competitive supply chain to increase the productivity of laser-based AM and to bring it a significant step further towards larger scale industrial manufacturing. In order to upscale the results and to reach an industrial relevant level of productivity, the project is focused on the following four main challenges (i) Part modeling and topology optimization (ii) Raw material optimization to avoid powder contamination (iii) Process optimization, including innovations of the control software of the AM machine, to enable high throughput production (iv) Setup of laser-PBF of nanostructured Titanium alloys with unchanged granulometric dimension for an additional push to higher productivity, since nanostructured metal powders can be sintered with lower energy input and faster speed. The project, thanks to the three end-users involved, is focused on components for prosthetic, automotive and moulding applications to optimize the procedure for three different materials, respectively titanium, aluminium and steel.

Manutelligence targets the product-service emerging trend; aiming at providing to EU manufacturing companies: - Efficiency in the design process, through ubiquitous cross-disciplinary collaborative management of P-S engineering knowledge across the entire life-cycle phases; - Complete integration of Product Lifecycle Management and Service Lifecycle Management, using methodologies and tools to support cross development; - Involvement of all the key partakers in the supply chain, including customers; - The ability to Search, retrieve and reuse data from heterogeneous data sources during design, manufacturing, testing and usage; - To manage, reuse and optimize designs, promoting modularity and Engineering Design Codified Knowledge, through KBE and design automation; - Close knowledge loop cycles between design, manufacturing, testing and use of products; - To extend and improve the use of Simulation and optimize it through comparison with test bench and real usage data; - Precise and quick measures and simulations of Cost and Sustainability issues, through Life Cycle Cost (LCC), Life Cycle Analysis (LCA) and CO2 footprint . To achieve these needs, ManuTelligence aims to integrate best in class methodology and tools from research and industry, resulting in a secure, cross disciplinary collaborative Product/Service Design and Manufacturing Engineering Platform. This platform will enable designers and engineers to access through natural 3D experiences to data from both the traditional enterprise IT systems (CAD, CAX, PLM, MES, etc.) and IoT enabled systems for physical products information and knowledge management. Such a platform, to have success on the market, needs to be inclusive, facilitating the cooperation and collaboration of enterprises. For this reason, it has been decided from the draft architecture, that it will have interfaces based on Open Standard (e.g. STEP and the OpenGroup QLM.

SiGNE will deliver an advanced lithium-ion battery (LIB) aimed at the High Capacity Approach targeted in this work programme. Specific objectives are to (1) Develop high energy density, safe and manufacturable Lithium ion battery (2) optimise the full-cell chemistry to achieve beyond state of art performance (3) Demonstrate full-cell fast charging capability (4) Show high full-cell cycling efficiency with >80% retentive capacity (5) Demonstrate high sustainability of this new battery technology and the related cost effectiveness through circular economy considerations and 2nd life battery applications built upon demonstrator and (6) Demonstrate high cost-competitiveness, large-scale manufacturability and EV uptake readiness. SiGNE will achieve these objectives by incorporation of 30% Si as a composite where it is electrically connected to the Graphite in nanowire form. This will realise a volumetric ED of >1000 Wh/L when pre-lithiated and paired with a Ni- rich NCM cathode optimised to deliver 220 mAh/g. This will be further enabled by a specifically designed electrolyte to maximise the voltage window and enable stable SEI formation. A sustainable fibre based separator with superior safety features s in terms of thermal and mechanical stability will be developed. SiGNE will establish the viability of volume manufacturing with production quantities of battery components manufactured by project end. The battery design and production process will be optimised in a continuous improvement process through full cell testing supported by modelling to optimise electrode and cell designs through manufacture as a 21700-type cylindrical cell and prototype testing at by OEMs. (SOH) monitoring across the entire battery lifecycle will optimise safety 2nd use viability. SIGNE will go significantly beyond SoA with recovery of anode, cathode and electrolyte components. In this circular economy approach recovered materials will be returned to the relevant work package to produce new electrodes.