WAVETAILOR

A central concern here is defect-free, sustainable first-time-right production that fulfils the high requirements . The focus is on developing an energy-efficient photonic system based on modular laser sources and optics that can utilise different wavelengths (innovative diode lasers). Diode lasers are 20 to 30 % more energy efficient than conventional laser technologies. This means that powder bed-based 3D printing processes (L-PBF) and laser metal deposition (L-DED) are more energy-efficient, component quality is improved and the number of metal-based material types that can be processed can be increased. The use of digital twins makes first-time-right production possible. The AI models developed in the process learn the cause-and-effect relationship between the production parameters and component quality from the recorded production data and suggest improvement measures in production planning. This reduces waste, energy consumption and production costs. The successful implementation of innovative technologies is expected to reduce energy consumption by 200 MWh and produce almost 1000 kg less waste, while at the same time reducing production costs by 50-65%. These sustainable benefits are to be confirmed by a comprehensive sustainability study.