NEW DELI PROJECT

NewDeli is part of the APPOLO project, which aims to establish and coordinate connections between end-users, applications laboratories and equipment manufacturers in the field of emerging innovative laser technologies.
Objective

New Deli wants to propose a new ultra-short pulse fiber delivery system, whose objective is to be the key enabling factor for the new generation of additive and subctractive manufacturing.

Specifications

The NewDeli delivery system is based on a hollow core photonics crystal fiber (HC-PCF) that allows ultra-short pulsed beam delivery in a cable, giving the possibility of coupling with an anthropomorphic robot with an unprecedented degree of flexibility.

Applications

New Deli’s solution has been specifically developed for med-tech, automotive and aerospace sectors where the industrial demand is characterized by extremely high manufacturing costs because of extreme part complexity, low volume and pricey raw material.

STATE OF THE ART: COMPLEX FREE-SPACE OPTICAL CHAINS

The AM equipment currently uses optical solutions that are particularly limiting  because of complex free-space optical chains to route the pulsed beam to the working area. Such an approach can be fitted on a gantry, but it’s practically impossible to install on an anthropomorphic robot.

imgmacchina

NEW DELI SOLUTION: HIGH FLEXIBILITY

New Deli solution gives the possibility to decouple the optimization of the machine dynamic behavior with respect to the system of positioning of the laser without the constraints forced by the very low flexibility given by the gas-based delivery system. The indipendence of the laser source position with respect to the working area allows better flexibility in terms of working conditions (lower temperature, less mechanical vibrations etc.…), thus increasing the lifetime of the whole system and reducing the machine set-up time.

arm

KAGOME FIBER: REPETITIVNESS OF THE WORKING CONDITIONS

The drawback of using a fiber delivery system resides in the fact that the same fiber can introduce in the system an additional source of loss: it could reduce the quality of the beam and increase energetic losses. The losses are predictable and remain constant during the whole life of the fiber (neglecting losses of performances due to aging). This aspect has a fundamental importance for industrial applications because it overcomes the unpredictability of the variation of the delivery medium’s conditions in gas-based systems. The repetitiveness of the working conditions that can be achieved with a fiber based delivery system far exceeds the one of traditional systems.

HCPCF-2

Workplan

Task 1: Industrial process requirements

IRIS will define a set of requirements concerning the industrial process, both in terms of quality of the parts to be produced by AM using OPI’s delivery system and in terms of throughput. Based on this input, IRIS will work with OPI to translate the industrial requirements into specifications for the delivery system. These specs will be used for a first characterization of the delivery system by BUAS. Moreover IRIS will agree with BUAS a suitable validation experiment representative of IRIS industrial process, which will constitute the final validation of OPI’s delivery system.

Task 2: Alpha samples realization

Based on D1.2, OPI will customize its current kagome fibre based device. These so called “alpha” samples are supposed to meet the functional specifications but not the quality and reliability requirements.

Task 3: Alpha samples characterization

At BUAS’ application lab, OPI and BUAS will perform alpha samples characterization based on D1.2 functional specifications.

Task 4: Beta samples realization

Taking into account the outcome of D3, OPI will modify alpha samples design and produce the final release of the delivery system (“beta samples”). Beta samples are supposed to be a production ready design, which should meet all functional specification as well as be able to pass successfully the qualification phase.

Task 5: Beta samples characterization

At BUAS’ application lab, BUAS and OPI will perform beta samples characterization based on D1.2 functional specifications.

Task 6: Industrial validation experiment

At BUAS’ application lab, BUAS, IRIS and OPI will perform the industrial validation experiment devised in D1.3 in order to assess the applicability to the industrial use case. The experiment set-up will start right after Task 1 completion in order to verify the consistency of the functional specifications defined by D1.2 with the requirements of D1.1, by using the alpha samples. The task will be concluded by demonstrating beta samples’ full compliance to D1.1 requirements.

Task 7: Quality and reliability assessment

This task will be devoted to prove the robustness of the delivery system and its ability to meet production grade quality and reliability.

Task 8: Dissemination and exploitation

Activities:

  • Specific 3-monthly newsletter to APPOLO partners
  • Project web page linked to/from APPOLO webpage
  • Specific event held at the end of the project at OPI’s facilities in Torino open to all APPOLO network (target audience 50 persons)
  • Hosting a seminar in Torino open to young researcher from APPOLO network where to present NewDELI open knowledge (target audience 10 persons)

Status

TASK 1: Industrial process requirements100%
TASK 2: Alpha samples realization100%
TASK 3: Alpha samples characterization100%
TASK 4: Beta samples realization100%
TASK 5: Beta samples characterization 100%
TASK 6: Industrial validation experiment100%
TASK 7: Quality and realiability assessment100%
TASK 8: Dissemination and exploitation100%

PARTNERS

NEW-DELI gathers together two SMEs, a technology provider (OPI) and an end-user (IRIS), and a lab belonging to the Appolo hub (BUAS) to experimentally assess a cutting edge ultra-short pulse fibre delivery system in a practical use case with a definitely relevant potential market since it targets the next generation of additive-subtractive manufacturing machines.

BUASswitzerland-flag

Laser application laboratory


Bern University of Applied Sciences is a multi-disciplinary, application-oriented university with a strong background in laser micromachining, applied fiber technology, thin film processing and materials analysis.

Website

IRISit

End-user


IRIS is a start-up company founded in 2012 with great expertise on development and qualification of new industrial processes/equipment solutions for laser and plasma processing technologies.

Website

OPIit

Component supplier


OPI Photonics is a small limited liability Italian company incorporated at the end of 2012; it has the mission to develop custom solutions in response to specific needs of the high-power laser source manufacturers.

Website

NEWS&EVENTS

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26Nov

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The Project Kick-Off Meeting has been held on 2015 November 26 at Universidad Politécnica de Madrid. The Appolo Project activities include a list of assessment.. Read More →

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