KARMA

Knowledge Based Process planning and Design for Additive Layer Manufacturing

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 Obiettivo del progetto (Objective)

'Mass production is shifted towards the countries with lower factor cost. European industry must search for a chance in customized and hi-tech products, trying to take advantage of its supremacy regarding new technologies development. Aerospace industry, automotive industry, medical implants, hi-end equipments industry, consumer products, protection and safety are the target sectors –which include more than a million of European enterprises in real need of customized product. Additive Layer Manufacturing (ALM) -also known as Free Form Fabrication and formerly Rapid Manufacturing-, is a novel fabrication method of parts directly from the electronic model by layer manufacturing, using active principles such as laser and Electron beams. Currently, ALM is the first and the best option for short series of customized products. However, layered manufacturing is not without challenges. Part properties, dimensional accuracy and surface quality depend strongly on process planning, and sometimes prevent ALM parts to be considered as fully functional. The objective of KARMA is to respond to above mentioned challenges with a knowledge-based engineering system (KBE) that can estimate functional properties of ALM parts automatically and in short time. The KBE system would define the optimal production parameters automatically and execute a virtual test of the fabricated part. The KBE system will include a database with characterized material and part properties for all major ALM technologies. The development of such a KBE system is a difficult and demanding task, which will involve both ALM users and companies from the final customer sectors. A combination of mass production metal IAGs (FEMEVAL) and ALM IAGs (ASERM, AFPR and RAPIMAN) set up the proposal as a cohesion factor between material providers, technology providers, part fabricants and end-users to promote ALM knowledge among all of them.'

Introduzione (Teaser)

Process planning tools customise products

Descrizione progetto (Article)

Cost-effective production techniques with fast set-up times and high flexibility are required to produce specialised parts for industries such as aerospace and biomedicine. Additive layer manufacturing, also called rapid manufacturing, is perfectly suited to the task. It builds up parts of complex geometries by adding successive layers of materials via instructions from a computer-aided design file.

Process planning tools developed within the context of the EU-funded project 'Knowledge based process planning and design for additive layer manufacturing' (http://www.karmaproject.eu (KARMA)) will enable fast and easy optimisation, encouraging greater uptake and European supremacy in the field. Previously, selection of the appropriate additive layer manufacturing technology and setup of process parameters required extensive experience and in-house expertise.

Partners from complementary areas worked closely on the demanding task of developing a knowledge-based engineering system to guide process setup and control. A database of material properties and part properties covers four major additive layer manufacturing technologies and eight common materials.

An 'Expert Process Planning' tool utilises the knowledge-based engineering system to help manufacturers choose the appropriate technology, material and build scenario for their specific part. The tool quickly and automatically estimates functional properties of the part, defining optimal process parameters and executing a virtual production test. The KARMA tool enhances design efficiency and final product quality through rapid design and production of high-quality customised parts for high-tech sectors. This in turn, also facilitates certification in sectors with rigid regulations such as the aerospace and biomedical fields.

KARMA has created a user-friendly knowledge-based engineering tool for European manufacturers that will have a major impact on the EU economy. Exploitation plans are currently being drafted among partners. European industries will soon be able to cost-effectively rely on EU labour to get new products to market.