Climate Neutral and Digitalized Laser Based Surface Functionalization of Parts with Complex Geometry

在未来几年，欧洲工业必须承担采用清洁和气候中立的工业价值链，生产可持续产品的挑战。采用数字系统将通过创新的生产流程从根本上改变产品和服务行业。特别是，完全数字化的基于激光的增材制造方法非常通用，因此可以在不同的行业中实施。此外，还可以通过设计优化实现对传统制造和材料浪费的节能。然而，这些零件还需要额外的表面处理，这是目前的能源和材料消耗，增加成本和危害环境。此外，必须开发提高增材制造零件附加值的新概念，例如，在关键应用中生产先进的表面功能。CLASCO项目的主要目标是开发一种通用的数字化激光后处理路线，用于创建具有复杂形状的功能化AM部件。虽然复杂的零件将通过激光粉末床融合生产，但使用直接激光干涉图案化的激光抛光和激光表面微结构将结合在一个独特的制造系统中。这条路线将取代几个消耗资源的过程，减少对环境的负面影响。该实施将允许替代标准的环境非友好方法，甚至获得更好的性能。此外，还将采用不同的在线监测方法，特别是等离子传感器和红外摄像机。通过这种方式，每个部件的过程的虚拟表示将成为可能（数字孪生），从而创建完全数字化的产品。该项目的影响将被分析，以优化整个生命周期的流程和产品的可持续性。

In the coming years, the European industry must assume the challenge of adopting clean and climate-neutral industrial value chains, producing sustainable products. Adopting digital systems will radically change the industry with products and services through innovative production processes. In particular, fully digitalised laser-based additive manufacturing methods are very versatile and thus can be implemented in different industries. Furthermore, energy saves against conventional manufacturing and material waste but also by design optimization can be achieved. However, these parts also required of additional surface treatments, which are nowadays energy and material-consuming, increasing costs and harming the environment. In addition, new concepts for increasing the added value of AM parts must be developed, for instance, by producing advanced surface functionalities in critical applications. The main objective of the CLASCO project is to develop a universal and digitalised laser-based post-process route for creating functionalised AM parts with complex shapes. While the complex parts will be produced by Laser Powder Bed Fusion, Laser polishing and laser surface micro-structuring using Direct Laser Interference Patterning will be combined in a unique manufacturing system. This route will substitute several resource-consuming processes, reducing the environment's negative impact. The implementation will allow substituting standard environmental non-friendly methods and even obtaining a better performance. In addition, different in-line monitoring methods, specifically plasma sensors and infrared cameras will be implemented. In this way, a virtual representation of the process for each part will be possible (digital twin), creating an entirely digitised product. The project's impacts will be analysed to optimise the sustainability of processes and products across the entire life cycle.