BOOST3DMETAL
Enhancing Metal Additive Manufacturing Through Advanced Surface Engineering
Transforming the production of aluminum components with cutting-edge Powder Bed Fusion technology and customized post-processing solutions
Project Overview
BOOST3DMETAL is a Eurostars-3 funded project aimed at revolutionizing aluminum metal additive manufacturing by integrating tailored surface treatment methods and digital tools. Focusing on the Powder Bed Fusion (PBF) process, the project addresses challenges in post-processing, enabling the cost-effective production of high-performance components for the transport sector.
1st June 2024
June 2024
30th November 2026
November 2026
4 Partners
2 Countries
Funding: €2,400,000
Eurostars
The Challenge
Post-Processing Complexity
Overcoming the high cost and complexity of surface treatment in intricate 3D printed geometries
Material-Specific Needs
Addressing unique challenges in aluminum alloy treatment and compliance with REACH regulations
Surface Analysis and Control
Developing precise inspection tools for hard-to-reach features like holes and recesses
Project Objectives
Design-to-Post-Processing Integration
Create comprehensive guidelines that align design, manufacturing, and surface finishing
Advanced Surface Treatment
Develop safe, effective, and REACH-compliant chemical treatments for aluminum components
Digital Quality Assurance
Implement software tools for surface morphology and roughness analysis, including borescope inspection
The Consortium
An expert alliance covering the full additive manufacturing process chain
Work Packages
Full Project Test plan and requirement update
Methodologies and requirements defined in WP1 will feed WP2 for the design of the test specimens and the formulation of specific products for the surface treatment of the selected alloy and the target finishing.
Development of Surface Treatment
WP2 comprises the development of suitable processes for surface treatment of simple and complex specimens with different possible microstructure and roughness that could be generated in an AM component, with the aim to provide the final part with the required functional properties.
Design rules for surface treatment and development of high-precision image based FEA analysis for the characterization of AM parts
This WP is aimed to develop a design software tool to assess the surface treatment of complex-shape components within the entire production chain and develop a high precision image-based FEA analysis for a complete characterization of roughness, morphology and covering power of AM parts
Prototype Testing, validation and Demonstration
This work package is devoted to validating the full process which includes the bath production, the design guidelines and software, and the production and characterization methodology.
Project Mangement, communication, dissemination and exploitation
Project management tasks and dissemination of results to the industry
Impact & Use Cases
Advanced Surface Treatments
Customized coatings and finishes reduce post-processing costs and improve corrosion resistance of aluminum parts.
Design-Integrated Manufacturing
New guidelines enable part designs that simplify post-processing and reduce production complexity.
Sustainable Lightweight Components
Promotes the use of recyclable aluminum alloys in aerospace and automotive, enhancing strength-to-weight efficiency.