Project Summary: OPeraTIC will develop a highly efficient and modular manufacturing platform to boost the adoption of high-power Ultra-Short Pulsed Lasers, as a sustainable alternative to current surface processing. The OPeraTIC open, interoperable and expandable architecture will tackle the industrial entrance barriers of laser microstructuring of large 3D parts. OPeraTIC provides the required productivity/quality through different developments: (i) combination of advanced optical modules for beam transport and manipulation (ii) dexterous and precision robotic manipulator. iii) AI-enhanced process planning and adaptability. OPeraTIC proposes a modular and automated routing of optical components guaranteeing versatility and replicability, i.e beam delivery (polarization maintaining fiber), management (dynamic control beam shaping) and metrology (novel optical setups for product & process monitoring).
On top of that, OPeraTIC will develop a system architecture for the upscaling of USPL machines to large envelope and complex trajectories, driven by a novel RAMI4.0-compliant controller (merging dexterous manipulation with high level CNC motion accuracy and full synchronization of motion, laser process and quality control). Finally, OPeraTIC proposes an I4.0-compliant platform for systematic data exchange and integrated bidirectional communication (Automation-ML and OPC-UA standards) between real environment and its digital representation. This end-to-end seamless connection enhances a Machine Intelligence Framework for the definition of Zero Defect Manufacturing (ZDM) strategies, empowered by AI and real-time monitorization and control, for process optimisation.
Scientific Output/Outcome Expected From the Project: OPeraTIC project will develop a highly efficient and modular manufacturing platform to boost the adoption of highpower USPL and advanced laser equipment in industry. The OPeraTIC open, interoperable and expandable architecture will be specially adapted towards microstructuring of large and complex parts, at the level of physical, information and control interfaces. Main objectives are:
- Modular architecture for high power laser microstructuring with large envelope and agile manipulation
- Closed-loop data driven pipeline and digital architecture for modular, reconfigurable, flexible and integrable USPL production line for large and complex components
- To develop a Machine Intelligence Framework for the definition of a ZDM strategy empowered by AI and real-time monitoring. & control at edge level and
- To demonstrate OPeraTIC approach in real-scale for the manufacturing of large-scale high-precision complex components, boosting results exploitation and enabling EU industry adoption.
Target Group of the Project: Main target groups are:
Technology: USPL ecosystem (developers & providers -laser sources, fibers, beam management tools, metrology), robotics, I4.0 components
Manufacturing: White goods, aeronautics, automotive, lighting/HMI
Stakeholders: standardisation entities, policy-makers, training organizations, certification bodies.
Scientific community (field of Photonics, ZDM manufacturing, I4.0), and society (youths, women, society...).
Importance of the project in Tackling Global Challenges: OPeraTIC will contribute to the adoption of advanced high power laser systems in high impact applications by developing the OPeraTIC Manufacturing Platform, and specifically, by providing new process planning strategies that will enhance quality of manufactured parts at higher productivity rates. OPeraTIC takes a comprehensive approach for enabling the laser micromachining of functional surface structures at high production rates, based on the knowledge on massive parallelization and custom beam distribution and their effect on laser-material interactions (parallelization strategies, beam distribution design rules and proximity effects). Based on such knowledge, specific elements of the system will be developed, such as a high coherence lightweight laser amplifier, dynamic beamshaping modules, models and abstract rules for material processing, and quality monitoring tools for large areas, together with closed loop processing strategies for zero defect manufacturing. OPeraTIC will implement an additional degree of freedom by on-demand optical routing of the laser beam through the available optical modules, making possible to select optical modules according to the specific needs of each application. Routing will be implemented in the OPeraTIC Manufacturing Platform in the different selected use cases that represent a variety of high demand and high impact industrial applications, demonstrating its versatility.
Scientific/Social/Economic Innovative Contribution: This project aims to make a significant contribution to scientific, social, and economic innovation areas. The primary goal of the project is to develop a new product or process that will benefit all sectors worldwide. However, innovation in services is also aimed to be achieved during the project process. If the project is successful, innovation will be disseminated in scientific, social, and economic terms.
Contribution to the Development of Professional Skills: This project also contributes to the development of professional skills and abilities. By collaborating with educational institutions, businesses, and other civil society organizations, the project will provide opportunities to acquire new skills and abilities. As a result, project participants will gain access to new job opportunities, contribute to the qualified workforce that businesses require, and progress in their careers.
Contribution to the Development of Human Resources: The project aims to make a significant contribution to the development of human resources. The activities carried out within the project are designed to contribute to the personal and professional development of the participants. As a result, project participants will develop themselves, acquire new skills, and become more competitive in the job market. In addition, the training and mentoring activities carried out as part of the project will help participants develop their leadership skills and ability to collaborate.
Information about the other partners in the project: The multidisciplinary OPeraTIC consortium covers the whole value chain through the research of innovative and green laser-based micromanufacturing solutions to be implemented in 4 industry driven use cases. 17 partnered consortia composed by 4 RTOs, 3 large companies, 9 SMEs and one association
