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Success stories from the MANUELA project

The MANUELA project has developed a world-class Pilot Line Production Service for additive manufacturing in metals. The services are all stemming from top-quality research and validation across industrial applications. Here you find 8 success stories – from space to medical.

Through the MANUELA project a pan-European manufacturing capacity has been created with a focus on metal additive manufacturing, specifically the powder bed fusion processes PBF-LB and PBF-EB. During the project different steps along the supply chain has been optimized and tuned, ranging from design and design optimization, material and process development, as well as post-operations using automated solutions to ensure best in class EHS work environment.

8 key realizations – from space to medical

Below are a few success stories to demonstrate the capacity of developed pilot line to ensure manufacturing of highly complex parts with the right properties. 

Automotive part – brake component

Customer and market: OEB srl Italy

Main goal: Flexible design and production time reduction

Material: Ti6246

Key challenges:

  • Design adaptation for AM
  • Minimize as much as possible the printing supports to reduce post-processing time

Automotive part – rocker component

Customer and market: OEB srl Italy

Main goal: Flexible design  and production speed increase 

Material: Ti6246

Key challenges:

  • Design adaptation for AM
  • Minimize as much as possible the printing supports to reduce post-processing time

Space part – slip ring rotor

Customer and market: Beyond Gravity (CH)

Main goal

  • Reduction of the number of parts
  • Integration of electrical functionalities

Material: Cu 997

Key challenges:

  • Integration of electrical functionalities
  • Printing of small features
  • Post-processing

Space part – slip ring stator

Customer and market: Beyond Gravity (CH)

Main goal: Reduction of mass (20%)

Material: A20X, Al2139

Key challenges:

  • Topology optimization while satisfying mechanical requirements for space environment
  • Post-processing

Medical part – cranial implant

Customer and market: CEIT (SK)

Main goal:  

  • Reduce manufacturing time via supports optimization
  • Deformation minimization

Material: Ti6Al4V ELI

Key challenges:

  • Printing orientation and supports definition
  • Part deformation

Avionics part – helmet optic support

Customer and market: Qioptic (UK)

Main goal:  

  • Mass reduction
  • Cost and manufacturing time reduction

Material: A20X

Key challenges:

  • Printing orientation
  • Deformation
  • Post-processing

Energy part – fuel nozzle

Customer and market: Siemens (SW) 

Main goal: Reproduce the part in AM

Material: Hastelloy X

Key challenges: Small internal features

Energy part – combustor

Customer and market: ENEL (IT) 

Main goal: Reproduce the part in AM

Material: Hastelloy X

Key challenges:

  • Print in multiple parts with final reassembly
  • Deformation
  • Post-processing

Energy part – injector

Customer and market: ENEL (IT)

Main goal: Reproduce the part in AM

Material: Hastelloy X

Key challenges:

  • Print in multiple parts with final reassembly
  • Post-processing

 

More information

In MANUELA's booklet you will find more information about some of the use cases.

Download more information

Horizon 2020-funded

MANUELA project has received funding from the European Union's Horizon 2020 Research and Innovation Programme under Grant Agreement N°820774. Read more

 

Please contact us if you would like further information on any of our use cases.

Seyed Hosseini

Contact person

Seyed Hosseini

Forsknings- och Affärsutvecklare (FOA)

+46 10 228 47 57

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