Modular Laser Sources For Sustainable Production Of Short Personalized Production Series (WAVETAILOR)

WAVETAILOR专注于与复杂的多材料组件和装配相关的两个工业场景。第一个是高超音速氢驱动飞机的多材料前缘的定向能量沉积，而第二个涉及用于城市交付的无人机的复杂多材料组件的粉末床融合。这两种情况下的挑战都与零缺陷制造、可持续性和首次正确制造有关。WAVETAILOR旨在解决复杂材料结构制造中的高精度、零部件的拆卸、再利用和回收，同时减少制造过程和零部件本身的环境足迹。为了实现这一目标，该项目开发了三个主要支柱：1）基于模块化二极管激光源和多波长光学器件的灵活节能光子设置; 2）该设置的完全可重构性，以在两个用例的制造中使用最少的能量和材料资源，以及3）在装配级的ZDM和ZDW策略，控制在机器级的复杂多材料产品的顺应性，车间层和异地制造链层。后一个支柱将基于数字兄弟（车间级）和孪生（云级），用于自动评估零部件/装配设计的圆度;使用合成遗留数据和基于真实的时间流程和后流程监控的ZDM/ZDW进行首次正确的流程规划。当WAVETAILOR的目标实现时，两个用例的制造过程将减少200 MWh的能源消耗，减少923 kg的废物，同时生产成本将降低50-65%。为了证明这一点，沿着项目提供了专门的可持续性研究。

WAVETAILOR focuses two industrial scenarios which are related to the complex multi-material component and assembly. The first one is Directed Energy Deposition of a multimaterial leading edge for a hypersonic hydrogen-driven airplane, while the second relates to the Powder Bed Fusion of complex multi-material assembly of a drone for urban delivery. The challenges in both cases are related with zero defect manufacturing, sustainability and first-time-right manufacturing. WAVETAILOR aims to solve the high-precision in complex material structure manufacturing, the disassembly, reuse and recycling of components, while reducing the environmental footprint of both manufacturing process and the components itself. To achieve this, three main pillars are developed in the project: 1) flexible energy efficient photonic setup based on modular diode-based laser source and multi-wavelength optics; 2) full reconfigurability of this setup, to use minimal energy and material resources in manufacturing of two use cases and 3) ZDM and ZDW strategies at assembly level controlling the compliability of complex multimaterial products at machine level, shop floor level and delocalized manufacturing chain level. The latter pillar will be based on digital sibling (shop floor level) and twin (cloud level) for automatic assessment of component/ assembly design for circularity; first-time right process planning using synthetic legacy data and ZDM/ZDW based on real time process and post-process monitoring. When the WAVETAILOR objectives are achieved, the manufacturing process of the two use cases will have spent 200MWh of energy less, 923kg of waste less, while the production costs are going to be 50-65% lower. In order to prove this a dedicated sustainability study is provided along the project.