The EU-funded ALABAMA project aims to address persistent challenges in additive manufacturing, such as porosity and inconsistent microstructure, by advancing adaptive laser technologies.
Project Description
Challenges such as porosity and inconsistent microstructure continue to hinder the industrial adoption of additive manufacturing (AM). In this context, the EU-funded ALABAMA project offers an innovative solution. The project aims to advance adaptive laser technologies for AM by shaping laser beams both spatially and temporally. This approach seeks to reduce porosity and precisely tailor the microstructure of materials. Through the development of advanced physics-based models and real-time monitoring, ALABAMA aims to optimise AM processes.
This initiative is timely, as industries such as aviation, maritime, and automotive grapple with challenges including distortions, residual stresses, and quality control. ALABAMA’s holistic approach promises to revolutionise manufacturing by increasing productivity, reducing defects, and paving a sustainable path forward for European industry.
Objective
The ALABAMA project focuses on developing and maturing adaptive laser technologies for AM. Its primary objective is to reduce porosity and tailor the microstructure of deposited materials by shaping the laser beam both spatially and temporally during the AM process. Key innovations include the development of multiscale physics-based models to optimise AM process parameters. These parameters will be tested and matured for multi-beam control, laser beam shaping optics, and high-speed scanning.
To ensure process quality, advanced online monitoring and closed-loop control will be implemented. Techniques such as multi-spectral imaging, thermography for melt pool behaviour monitoring, wire-current measurements, and high-speed imaging will be employed. These will enable precise control of the AM process. Additionally, advanced material characterisation will be conducted on coupons and specific use cases to verify compliance with performance requirements.
The matured technologies will be tested in three use cases—aviation, maritime, and automotive—spanning a wide range of manufacturing volumes, from low-production, high-value components to high-production, cost-sensitive parts. These sectors face common challenges, including distortions, residual stresses, and material quality issues. ALABAMA’s demonstrators aim to improve distortion compensation during AM, reduce build failures caused by residual stresses, minimise porosity, and enhance microstructure tailoring.
Overall, the project is expected to deliver:
- Up to 100% increase in process productivity.
- 50% reduction in defects.
- 33% cost reduction through increased productivity and energy savings.
- 15% reduction in greenhouse gas emissions.
- First-time-right manufacturing enabled by simulation, process monitoring, and adaptive control.
End users will adopt the developed technologies, while sub-technologies from the work packages will be commercialised. This will strengthen European industry by enhancing autonomy and resilience.