List of FoF AM related projects. The cluster e-database with more details on these and more projects form other calls  appears in the website.



PhoCam: Photopolymer based customized additive manufacturing technologies (FoF.NMP.2010.2)                 

Phocam aims to develop innovative lithography-based additive manufacturing systems which will facilitate the processing of photopolymer-based materials in the new factory environment. It brings together industrial expertise and knowledge in the fields of supply chain and quality management, software development, photopolymers and ceramics, high-performance light sources, as well as systems integration so as to provide a fully integrated process chain.

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Amaze: Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products (FoF.NMP. 2012-4)

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%.

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.

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HYPROLINE: High performance Production line for Small Series Metal Parts (FoF.NMP.ICT.2012-4)


By further developing the manufacturing process itself as well as by research and application work on materials, pre and post treatment of the parts produced and supporting software Hyproline adds capabilities to commercially available manufacturing systems, in terms of speed, product quality and versatility. By keeping focus on the entire process from conceptual outline of the product via product design, engineering and production planning to actual manufacturing and control of quality, the project contributes to the development of a versatile manufacturing process, suited for industrial production by SMEs of complex custom made metal (meso scale = order 10 mm) parts in small batches or even in one-of-a-kind production mode.


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HiPR: High-Precision micro-forming of complex 3D parts (FoF.NMP.2012-5)

The primary goal of HiPr is to develop and integrate all necessary base technologies which create the basis to control and monitor the condition of micro-tooling for complex high-precision 3D parts. This will be achieved by developing and integrating: in-depth process and material knowledge, in-line measurements, real-time predictive maintenance. The knowledge-based HiPr results are also applicable in different sectors, leading to low defects, despite customisation trends.

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SMARTLAM: Smart production of Microsystems based on laminated polymer films  (FoF.NMP.2012-5)

SMARTLAM will create a new paradigm for process integration in rapid prototyping and rapid manufacturing of 3D micro products. The  3D-Integration approach (3D-I) combines new material properties with state of the art, scalable 3D technologies such as aerosol jet printing or different laser based processes for combined micro milling, microstructuring and surface functionalisation, micro welding and micro cutting .

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3D-HIPMAS:Pilot Factory for 3D High Precision MID Assemblies (FoF.NMP.2012-5)

Due to the high potential of miniaturization and integration, with regard to the innovation degree, quality and sustainability requirements, the 21st century looks forward to the integration of new functions on plastic parts to produce smart plastic products, as markets are requiring traceability, security, communication as well as ergonomics. So called Molded Interconnected Devices (MID) basically combine all the features of molded plastic parts with electrical conductive circuitry and electronics components assembly directly on the plastic packaging. MID lead finally to highly integrated multi-material and multifunctional 3D compact systems. With a 20% of growth per year since 2008, MID is the tomorrows converging technology for electronics and plastics.

3D-HiPMAS will overcome these challenges by providing the EU industry with a pilot factory based on 4 key technological building blocks enabling the manufacturing of low costs and high precision 3D multi-materials parts. These 4 technologies will be integrated in order to launch the future EU pilot factory

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Hi-Micro: High Precision Micro Production Technologies (FoF. NMP.2012-5)

The Hi-Micro projects intends to realise an innovative approach for the design, manufacturing and aquiality control of tool inserts to achieve significant breakthrough in mass production of precisition 3D micro-parts, through further developing both enabling manufacturing technologies, includidn additive manufacturing (AM), micro electrical discharge machining (micro -EDM), micro electro-chemical machinign (micro-ECM) and micro-milling and unique metrology and quality control methods such as computer-tomography (CT) metrology and digital holography. Together with industrial technology providers, the Hi-Micro project will furhter bolster the perfomance of industrial equipment for mass production of precisition 3D micro-parts, through modular design of toll inert units with improved thermal management capability, development of on-machine handling system and in-line quality control device. Activities will run over the entire value chain of mass production of precision 3D micro-parts, from product and tool insert design, manufacturing of tool inserts, micro injection moulding processes, to the production equipment and quality control in th whole production chain.

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AMCOR: Additive Manufacturing for Wear and Corrosion Applications (FoF.NMP.ICT.2012-7)

The overall aim of the AMCOR project is to develop and demonstrate a flexible and automated manufacturing process for the repair, coating and near net shape production of components composed of functionally graded materials (FGMs).

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CassaMobile: Flexible mini-factory for local and customized production in a container (FoF.NMP.2013-6)

The CassaMobile concept aims to provide local, flexible and environmentally friendly production of highly customised parts. The production system is based on a truly modular architecture, allowing rapid adaptation to new requirements. This ‘plug & produce’ architecture includes mechanical and control system adaptation. The footprint of the CassaMobile production container is minimised to enable transportation to and deployment in areas with severely limited space, whilst minimising investment and infrastructure costs.

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Optician2020: Flexible and on-demand manufacturing of customized spectacles by close-to-optician production clusters (FoF.NMP.2013-6)

Optician2020 will develop distributed manufacturing assets in mini-factories clustered in urban areas combining short series manufacturing technologies and ICT tools for design, process automation and on-line real time delivery management of personalised spectacles, a fashionable product combining health prescription, functional performance and aesthetical requirements.

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ADDFACTOR: ADvanced Digital technologies and virtual engineering for mini-Factories (FoF.NMP.2013-6)

In today globalized world, companies are trying to remain competitive through the adoption of a strategy where high quantity production of goods is the leverage to reduce costs. By negating this approach, ADDFactor proposes the Mini-factories concept, which is conceived to be an innovative solution for most of the actors involved in the whole supply chain: the relationship between retailers and the manufacturing technologies will be considered and characterized by a new production framework concept, founded on central knowledge-based design and local distributed manufacturing.

This high-level concept will be applied focusing on need-driven products, and ADDFactor will manage the complexity of their design phase thanks to a direct connection with the retailer, that will provide biometric data of the customers as tacit requirements and aesthetics tests as explicit demands, being both fundamental for an effective individual personalization. ADDFactor achievements will be focused on two different levels of manufacturing solutions, which will be placed:

- At retail environment, to consider products simple and/or reduced in terms of assembled components (i.e. orthotics or modular fashion heels and plateau);

- And at district level when the products are complex and the manufacturing procedures cannot be scaled at local level (i.e. sport shoes or complete customized fashion shoes).

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MANufacturing decision and supply chain management SYStem for additive manufacturing (FoF.NMP.2013-9)


ManSYS aims to develop and demonstrate a set of e-supply chain tools; to enable the mass adoption of Additive Manufacturing (AM). This will allow businessesto identify and determine the suitability of AM for metal products, and subsequently manage the associated supply-chain issues and ‘facilitating’ open product evolution.

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NEXTFACTORY: All-in-one manufacturing platform for system in package and micromechatronic systems (FoF.NMP.2013-11)

The mission of the NextFactory project is to develop and validate a new type of all-in-one manufacturing technology combining, for the first time, in a single piece of equipment, 3D freeform printing and ultra-precision 3D assembly. This highly flexible and scalable facility will empower microsystem manufacturers - and in particular SMEs - to effectively produce highly miniaturised Smart Products-in-Package (SPiPs) both in small series and high-throughput production of large parallel batches.

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ToMAX: Manufacturing processes for complex structures and geometries with efficient use of material (FoF.2014.2)

Lithography based additive manufacturing technologies (L-AMT) are capable of fabricating parts with excellent surface quality, good feature resolution and precision. ToMax aims at developing integrated lithography-based additive manufacturing systems for the fabrication of ceramic parts with high shape complexity. The focus of the project is to unite industrial know-how in the field of software development, photopolymers and ceramics, high-performance light-sources, system integration, life cycle analysis, industrial exploitation and rewarding end-user cases.

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Borealis: the 3A energy class Flexible Machine for the new Additive and Subtractive Manufacturing on next generation of complex 3D metal parts (FoF.2014.2)

Borealis project presents an advanced concept of machine for powder deposition additive manufacturing and ablation processes that integrates 5 AM technologies in a unique solution. The machine is characterized by a redundant structures constituted by a large portal and a small PKM enabling the covering of a large range of working cube and a pattern of ejective nozzles and hybrid laser source targeting a deposition rate of 2000cm3/h with 30 sec set-up times. The machine is enriched with a software infrastructure which enable a persistent monitoring and in line adaptation of the process with zero scraps along with number of energy and resource efficiency optimization policies and harvesting systems which make the proposed solution the less environmental invasive in the current market.

Borealis project targets a TRL 6 and will provide as outcome of three years work two complete Borealis machine in two dimensions : a lab scale machine and a full size machine, which are foreseen to be translated into industrial solution by 2019.

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REPROMAG: Resource Efficient Production Route for Rare Earth Magnets (FoF.2014.2)

The overall objective of the REProMag project is to develop and validate an innovative, resource-efficient manufacturing route (SDS process) for Rare Earth magnets that allows for the economically efficient production of net-shape magnetic parts with complex structures and geometries, while being 100% waste-free along the whole manufacturing chain.

The new Shaping, Debinding and Sintering (SDS) process for Rare Earth magnets is an innovative automated manufacturing route to realise complex 3D- and multilayered parts; resulting in a significant increase in the material efficiency of at least 30% during manufacturing; while at the same time allowing additional geometrical features such as threads, cooling channels, small laminations/segments (e.g. to increase the efficiency of electrical motors) and structural optimisations such as lightweight-structures or the joint-free realisation. As part of the project, the possibility to produce hybrid parts such as an improved moving-coil transducers for headphones, loudspeakers and microphones will be evaluated. The SDS process allows a new level of sustainability in production, as the energy efficiency along the whole manufacturing chain can be increased by more than 30% when compared to conventional production routes. In short, the innovative REProMag SDS process has the potential to manufacture complex structures of high quality and productivity with minimum use of material and energy, resulting in significant economic advantages compared to conventional manufacturing

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CAXMan: Computer Aided Technologies for Additive Manufacturing (FoF. 2015.08)

The objectives of Computer Aided Technologies for Additive Manufacturing (CAxMan) are to establish Cloud based Toolboxes, Workflows and a One Stop-Shop for CAx-technologies supporting the design, simulation and process planning for additive manufacturing. More specifically the objectives are to establish analysis-based design approaches with the following aims:-To reduce material usage by 12% through introducing internal cavities and voids, whilst maintaining component properties; -To optimize distribution and grading of material for multi-material additive manufacturing processes; and-To facilitate the manufacture of components which are currently impossible or very difficult to produce by subtractive processes (e.g., cutting and abrasive operations);-To enhance analysis-based process planning for additive manufacturing including thermal and stress aspects, and their interoperability with the design phase; -To enable the compatibility of additive and subtractive processes in production in order to combine the flexibility of shape in additive manufacturing with the surface finish of subtractive processes.

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Symbionica: Reconfigurable Machine for the new Additive and Subtractive Manufacturing of next generation fully personalized bionics and smart prosthetics (FoF.2015.10)

Symbionica project focuses on the manufacturing of personalized bionics, smart endoprosthetics and exo-prosthetics that require geometric and functional customization. The Symbionica concept integrates an innovative machine performing deposition of advanced materials and subtractive processes along with a supply chain distributed co-engineering platform for advanced design and full personalization involving all relevant stakeholders, design and engineering of the products and through-life services.
Symbionica manufacturing solution is conceived as a multi-material AM machine for material deposition and ablation, flexible and reconfigurable in the working cube, the material processing, the technology and the manufacturing strategy, with an advanced closed loop control methodology for product and process quality monitoring. This way products are manufactured in one processing step, complex in shape, 3D structured and joint free.

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