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.
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.
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.
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.
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.
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.
At BUAS’ application lab, OPI and BUAS will perform alpha samples characterization based on D1.2 functional specifications.
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.
At BUAS’ application lab, BUAS and OPI will perform beta samples characterization based on D1.2 functional specifications.
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.
This task will be devoted to prove the robustness of the delivery system and its ability to meet production grade quality and reliability.
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