The EU-funded METAMORPHA project will create a single, fully electric, digital device based on ultrashort pulse laser micromachining. It will replace the mechanical and chemical processes on many conventional production lines, while producing no chemical waste. Furthermore, being both agile and scalable, it promises to eliminate the need for thousands of production processes that negatively impact the environment.
Eco-friendly manufacturing processes protect the planet from exploitation and conserve natural resources. This makes global industry more sustainable and environmentally friendly. The EU-funded METAMORPHA project will create a single, fully electric, digital device based on ultrashort pulse laser micromachining. It will replace the mechanical and chemical processes on many conventional production lines, while producing no chemical waste. Furthermore, being both agile and scalable, it promises to eliminate the need for thousands of production processes that negatively impact the environment. A life cycle analysis (LCA) and social LCA will be performed to assess the environmental and socio-economic benefits.
"The METAMORPHA concept is a single agile USP laser micromachining platform to replace many conventional manufacturing process chains. It has the potential to eliminate thousands of environmentally damaging production processes. METAMORPHA is all-electric, all-digital, produces no waste chemicals and enables novel processes for product rework and repair.
All-in-one module: The key to this agility is a combination of two cascaded spatial light modulators (SLM) and a galvo scanner resulting in the most sophisticated beam shaping and steering ever developed. This allows a single module to perform the job of several laser processing heads: e.g. polishing, milling, drilling and cutting (importantly including any wall angle).
Made-to-measure laser processes: Each infeed component is scanned with a high resolution 3D sensor. A machine learning algorithm determines an individualised laser process to maximise efficiency and ensure ""first time right"".
In-line process control: Data from additional online sensors are processed using an edge device running a self-learning algorithm to provide real-time feedback for system control. The ultra-fast edge-based signal processing and synchronisation are key project topics.
Agile and scalable: Suitable for any standard industrial production line including 2-, 3- or 5-axis, rotating and roll-to-roll, and for scale up to parallel processing with multiple modules. The three end use cases (UCs) show the versatility and scope for replacing existing process chains:
UC-1 PHILIPS: Small complex metal parts (shaving heads) requiring 90 degree wall angles.
UC-2 TKSE: Large area embossing rollers and the re-writing of old rollers.
UC-3 CERAT: Very hard carbide parts and refurbishment of worn parts.
Sustainability assessment: A life cycle analysis (LCA) and social LCA will be carried out to quantify the environmental and socioeconomic benefits. A detailed plan for exploitation and an extensive dissemination and communication plan are in place."