BUILDING AN EUROPEAN ECOSYSTEM FOR PROTOTYPE MANUFACTURING IN THE AEROSPACE INDUSTRY

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1 BUILDING AN EUROPEAN ECOSYSTEM FOR PROTOTYPE MANUFACTURING IN THE AEROSPACE INDUSTRY APPROACHES ON TECHNOLOGY INTEGRATION Dipl.-Ing. Manuel La Rosa Betancourt M.A. FOUNDER & DIRECTOR PI INTEGRAL SOLUTIONS - GERMANY 2

2 CROSS CUTTING ACTIVITIES FOF INTEGRATION OF UNCONVENTIONAL TECHNOLOGIES FOR MULTI-MATERIAL PROCESSING INTO MANUFACTURING SYSTEMS. Integration of unconventional manufacturing technologies within a specific set based on an innovative concept. Aimed at radically and high risk new future technologies. DEADLINE (Two-stage Proposal-70 pages) CONTRIBUTION UP TO 5 MILLION EUR. Source: Horizon 2020 Cross Cutting Activities Work Program PI INTEGRAL SOLUTIONS - GERMANY 3

3 SCOPE OF THE CALL IS BASED ON RIA AT TRL S 4-6 Innovative Process Chains for high cost or critical multimaterial products Manufacturing processes capable of generating the features and geometries required for multimaterial products New flexible machinery concepts and components to allow the integration of unconventional technologies In-process inspection and control to ensure quality requirements within innovative process chain Source: Horizon 2020 Cross Cutting Activities Work Program PI INTEGRAL SOLUTIONS - GERMANY 4

4 EXPECTED IMPACT 10 % reduction of Production Time 15% reduction of production costs Resource efficiency by raw materials reduction of 10% Strengthened global position of European manufacturing industry Source: Horizon 2020 Cross Cutting Activities Work Program PI INTEGRAL SOLUTIONS - GERMANY 5

5 3. BUILDING AN EUROPEAN ECOSYSTEM FOR PROTOTYPE DEVELOPMENT PI INTEGRAL SOLUTIONS - GERMANY 6

6 ECOSYSTEM PILARS SMALL AND MEDIUM ENTERPRISES SME S INDUSTRIAL ADVISORY BOARD R&D INSTITUTIONS KNOWLEDGE NETWORKS KEY ENABLING TECHNOLOGIES (KET S) PI INTEGRAL SOLUTIONS - GERMANY 7

7 OBJECTIVES PRIMARY Developing a cyber-physical prototype manufacturing platform for critical components in the Aerospace industry based on collaborations between industry, R&D institutions an advisory board and knowledge networks. Aims Accelerating R&D Time Cycles Optimizing testing and validation costs Opening a new market for R&D institutions in Europe and SME s PI INTEGRAL SOLUTIONS - GERMANY 8

8 PROJECT CONCEPT 1 LINE OF RESEARCH 2 LINE OF RESEARCH PRODUCTION PROCESS AND COMPONENT DEPENDANT VARIABLES MATERIAL AND MICROSTRUCTURE SAMPLE DEPENDANT VARIABLES TRL 4 TRL 5 TRL 6 X X n Y Y n PI INTEGRAL SOLUTIONS - GERMANY 9

9 PROOF OF PRINCIPLE - AEROSPACE Deutsche Luft-und Raumfahrt Zentrum High Pressure Turbine Blades PARALELL PROTOTYPING APPROACH SAMPLE COMPONENTS ATOMISTIC SIMULATION FOR MODELLING AND MATERIAL SELECTION ADDITIVE MANUFACTURING VIA LMD AND SLM PLASMA SPHEROIDIZATION OF HIGH ENTROPY ALLOYS FOR BOND COAT AND TBC DEVELOPMENT OF BOND COAT AND TBC MATERIAL SYSTEMS WITH ADVANCED THERMAL SPRAY PROCESSES, EB-PVD, AND GAS FLOW SPUTTERING Forschung Zentrum Jülich ACCELERATED HIGH CYCLE FATIGUE TESTING FOR AM PROTOTYPE VALIDATION PI INTEGRAL SOLUTIONS - GERMANY 10

10 PROOF OF PRINCIPLE - ENERGY Deutsche Luft-und Raumfahrt Zentrum ATOMISTIC SIMULATION FOR MODELLING AND MATERIAL SELECTION Blades for Stationary Gas Turbines PARALELL PROTOTYPING APPROACH SAMPLE COMPONENTS ADDITIVE MANUFACTURING VIA LMD AND SLM PLASMA SPHEROIDIZATION OF HIGH ENTROPY ALLOYS FOR BOND COAT AND TBC DEVELOPMENT OF BOND COAT AND TBC MATERIAL SYSTEMS WITH ADVANCED THERMAL SPRAY PROCESSES, EB-PVD, AND GAS FLOW SPUTTERING ACCELERATED HIGH CYCLE FATIGUE TESTING FOR AM PROTOTYPE VALIDATION PI INTEGRAL SOLUTIONS - GERMANY 11

11 SMALL AND MEDIUM ENTERPRISES PI INTEGRAL SOLUTIONS - GERMANY 12

12 SMALL AND MEDIUM ENTERPRISES RECIPIENTS OF TECHNOLOGY TRANSFER STRONG INNOVATION BACKGROUND (EU PROJECTS) FOCAL POINTS FOR SUB-ECOSYSTEMS PI INTEGRAL SOLUTIONS - GERMANY 13

13 KEY ENABLING TECHNOLOGIES PI INTEGRAL SOLUTIONS - GERMANY 14

14 R&D INSTITUTIONS PI INTEGRAL SOLUTIONS - GERMANY 15

15 R&D INSTITUTIONS PI INTEGRAL SOLUTIONS - GERMANY 16

16 PI INTEGRAL SOLUTIONS - GERMANY 17

17 1. AEROSPACE AND ENERGY MARKET REMAINS ATTRACTIVE FOR VALUE CAPTURING BUSINESS MODELS BASED ON TECHNOLOGY 2. EUROPEAN INTEGRATION POLICY FRAMEWORK 3. EUPROMAP AS A FEASIBLE APPROACH TO ACHIEVE COMPLEMENTARITY 4. COMBINATION OF TECHNOLOGY INTEGRATION MODELS PI INTEGRAL SOLUTIONS - GERMANY 18

18 PI INTEGRAL SOLUTIONS - GERMANY 19

19 PI INTEGRAL SOLUTIONS LIMITED COLOGNE-GERMANY Tel Cel Dipl.-Ing. MANUEL LA ROSA M.A. PROJECT COORDINATOR Founder PI Integral Solutions Limited (Innovation Engineering and Strategic Outsourcing) Expertise: Nano Materials, Elastomers, Polymers, Project Management, Knowledge Management. PI INTEGRAL SOLUTIONS - GERMANY 20