Wavetailor Project: Modular laser sources for sustainable production of short personalized production series

The WAVETAILOR Project has been launched with the aim of revolutionizing the manufacturing and assembly of complex multi-material components. Focused on two industrial scenarios, the project addresses directed energy deposition for a hydrogen-powered hypersonic aircraft and powder bed fusion for an urban delivery drone. WAVETAILOR seeks to overcome challenges related to defect-free manufacturing, sustainability and first-time manufacturing precision.

This ambitious project has the collaboration of 11 entities: Lortek S.Coop., Joanneum Research, Coventry University, Europa no Luz, Aditivo Prima, Z Prime GmbH, Destinus España SL, Aerotecnic Metallic SL, Morfica SRL, the Austrian Agency . of Energy and Tematys. Each of these partners brings their experience and knowledge to drive WAVETAILOR‘s success.

WAVETAILOR‘s objectives are clear and ambitious. First, a flexible and energy-efficient photonic setup will be developed based on a modular diode laser source and multi-wavelength optics. This configuration will allow full reconfigurability, optimizing the use of energy and materials in the manufacturing of specific use cases.

Additionally, zero defect manufacturing (ZDM) and zero waste (ZDW) manufacturing strategies will be implemented at the assembly level, controlling the compatibility of complex multi-material products at various manufacturing levels. To do this, a digital twin at the plant level and a digital twin at the cloud level will be used, facilitating the automatic evaluation of the design of components and assemblies.

The expected impact of WAVETAILOR is significant. It is estimated that, by achieving its objectives, the project will reduce energy consumption by 200 MWh and reduce waste by 923 kg, while production costs will be reduced by between 50% and 65%. A specific sustainability study throughout the project will be responsible for demonstrating these advances.