Set up a sustainable open innovation ecosystem for efficient, low cost and fast upscaling of lightweight metal alloys and nanocomposites and related products, consisting of 6 operational building blocks
Determine administrative structure and define procedures and roles – avoiding any overlapping that can potentially lead to internal conflicts – securing a smooth operation of the ecosystem,
Establish a Non-for-profit Organization acting as a Single-Entry Point (SEP) for the clients of the ecosystem and undertaking the responsibility of administrative and legal aspects.
Clarify governance, organization and operational procedures, including knowledge management and IPR handling between the members of the Ecosystem as well as between the clients and the ecosystem
Develop a decision-making process in the ecosystem enabling the identification and evaluation of the needs of test cases brought by clients and translating them in upscaling, characterization and services workflows.
Enhance the operation and implement additional features to the 6 PL of the ecosystem in order to cope with the industrial requirements demanded by the customers (SMES, industries) in terms of novel lightweight products development including usage of nanoparticles.
Το integrate novel introduction method by ultrasound of nanoparticles in a batch process with suitable volume. For LPDC in a pilot scale production up to 150 kg and in rapid processing of small volumes for GSC.
To increase volume production of HPDC by optimizing the following processing parameters: melt volume, melt temperature, stirring rate (mechanical stirring), stirring vane design, ultrasonic probe shape/material and depth, ultrasonic frequencies and pulse rates, and melt feed rates into the shot die. Modelling can utilised to determine the effect of NPs on the die filling of the composite and thus limit defects. By determining the optimum NP addition levels, pouring temperatures, and plunger speeds scrap levels can be reduced thereby increasing production rates. The modelling will give insights into optimal casting for changing component geometries and alloys
For the WLAM pilot line, a specific procedure for process parameters development will be employed consisting of 3 steps: 1) definition of the AM setup, 2) DoE for process window adjustment and 3) validation through manufacturing of standard test artefacts5. All test results (imaging and material characterization), stored continuously in a DB, will speed up the development of new MMnC by WLAM based on previous developments stored in the DB making each new development faster.
Reduce by 70% the amount of faulty parts per day produced by the Borealis machine thanks to the integration of a closed loop control able to detect and correct online the deposition errors occurring during the DED process.
To enhance the operation of SPS-KOBO PL modification of SPS tool and tool assembling system, improvement of KOBO process and tool design to increase a PL productivity (up to 20-40%) and decrease the production cost (up to 30%). SPS-KOBO pilot line targets in the production of light weight bearing rings and profiles for cold forging of fasteners and other elements for aircraft/automotive industry from nanocomposite powders
Validate the proper operation of the ecosystem based on 8 selected test cases for upscaling, testing and demonstrating in operation environment of nanoenabled materials concept introduced by SMEs and industry demonstrating a 20% faster validation of materials compared to current SoA validation methodologies.
Launch an open call of interest for test cases (at least 10) dedicated to SMEs that will be able to access the ecosystem during the last two years of the project for free.
Proceed with improvements of operational procedures based on the feedback received from the test cases
To establish clustering and networking channels with EPPN (European Pilot Production Network), ΑΜ- Motion, European Materials Characterization and Modelling council etc., and other test beds (upscaling, characterization and modelling), particularly in the field of metal Alloys and composites, for cooperation and developing synergies towards a pan European integrated and sustainable ecosystem.
Collaborate with European initiatives including open data repositories (e.g. EPPN, Nanosafety cluster, enanomapper etc) and regulatory agencies.
Undertake communication/dissemination activities for promoting the ecosystem in targeted audiences, advertising the “success case” stories that will arise from the test cases.
To continuously update the initial business plan of the LightMe ecosystem
Liaise with potential investors (venture capitals and business angels) seeking extra funding and thus facilitating the access to funding for potential customers as well as with relevant Associations.