RES2AM funding for large-scale metal Additive Manufacturing demonstrator
The RESilient and RESource efficient Additive Manufacturing (RES2AM) project aims to advance sustainable, resilient manufacturing by achieving first-time-right production of large, complex metallic components using Laser Beam Powder Bed Fusion (PBF-LB). The project’s goal is to reduce material waste and energy consumption while ensuring high-quality output through real-time monitoring and process control.
Following a one-year feasibility study funded by Vinnova, based in Stockholm, Sweden, under the Net-Zero Impact Innovation programme, the RES2AM project has secured further funding to build a strategic system demonstrator. The project is coordinated by RISE, Sweden’s research institute and innovation partner, in collaboration with its academic partner Chalmers University of Technology’s Centre for Additive Manufacture – Metal (CAM2) and an international industry team from Sweden, Germany, Switzerland, and Australia.
Together, the project will look to tackle:
- Multi-sensor monitoring
- Digital QA & traceability
- Qualification
- Decision Support System (DSS)
The project is co-financed by Vinnova under the Net Zero Industry programme, with matched industrial contributions from GKN Aerospace Sweden, Nikon SLM Solutions, Saab, Ringhals AB, SKF Group, Quintus Technologies, Interspectral, AMiquam, Additive Assurance, Hexagon AB, MTC Powder Solutions, and Dyndrite.
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The Stage 1 Feasibility Study
The Stage 1 feasibility study aimed to develop sustainable and resilient Additive Manufacturing methods for producing large and complex metallic components using Laser Beam Powder Bed Fusion (PBF-LB). By prioritising ‘first-time-right’ production, RES2AM aims to achieve a 50% reduction in both material waste and energy consumption, laying the groundwork for a more efficient and environmentally friendly manufacturing paradigm. RES2AM addresses critical challenges in the production of large components, such as process monitoring, thermal stresses, process stability, and material handling.
The goal of the the stage 1 feasibility study was to demonstrate a resource-efficient and resilient manufacturing system with minimal environmental impact for producing large-scale metallic components for high-end applications such as aerospace and energy using Additive Manufacturing technologies. Additionally, a framework for life cycle assessment and a business model platform tailored to large-scale metal AM is being developed during the feasibility study stage, with plans for implementation in the next phase of the project.
Potential long-term effects include reduced material waste and energy consumption; creation of new business opportunities and markets, particularly in aerospace and energy; and strengthening Sweden’s role and EU leadership in manufacturing innovation through advanced technologies and collaboration.
