New research project focuses on efficient and sustainable production

Innovation Fund Denmark has just invested DKK 9 million in a major research and innovation project with, among other things, Aalborg University around new efficient and energy-saving laser processes in production companies, which must strengthen the competitiveness of Danish companies.

Several Danish companies that work with sheet metal processing and welding find that they can find it difficult to match foreign competitors on price. A new and improved laser manufacturing technology can help do away with that.

New laser-based technology is revolutionizing traditional production

A new research and innovation project will offer the plate processing industry a new laser-based technology capable of filling a gap between traditional plate processing machines and 3D printing.

- The project offers the opportunity to use traditional laser production technologies in a revolutionary new way, where we e.g. makes use of tailor-made laser beam patterns and laser bending, says project manager Morten Kristiansen, who is associate professor at the Department of Materials and Production at Aalborg University and continues:

- Several companies have experienced how the Industry 4.0 paradigm has transformed their production. In this project, we go a step further and include laser fabrication to this paradigm. As part of this, 3D laser measurements are used as an additional quality control of sheet metal blanks to achieve more accurate and cost-effective production.

Current plate manufacturing technologies on the market are indeed challenged, especially when it comes to the development of prototypes and small series, as it requires the use of several machines and manual labor.

One laser for everything

The technology developed in the project makes use of one laser which combines both cutting, welding and engraving in sheet metal, but also bending of metal, which is the missing piece in being able to produce complete sheet metal parts in an automated machine.

- With this project, Migatronic expects to be able to contribute further to both the degree of automation, efficiency and, not least, the quality of the processes in the sheet metal industry. We look forward to working with some of the best experts in the industry and have high expectations for the final product and the subsequent opportunities for Danish industry, says Kristian Morberg Madsen, director of the company Migatronic

The potential is great and helps to promote more sustainable production.

- At Grundfos, a large part of the products are manufactured in sheet material, which is traditionally shaped in metal tools, which require lubricants and subsequent washing before welding. The energy consumption for washing shaped plate blanks constitutes a very large proportion of the energy consumption in the total production. In addition, there is a need for both lubricants and chemicals for cleaning. With this project, it will be possible to produce sheet blanks completely without tools, lubricants, chemistry and energy for washing. In this way, it supports our ambitions for the sustainable production of energy-efficient products, says Jens Vestergaard Boll, Lead Specialist at Grundfos

The project takes its point of departure from the laser process automation group at the Department of Materials and Production at Aalborg University, which for over ten years and through several industrial research projects has been researching industrial high-power laser automation. This has resulted in the development of top competences within the area, where the group is at the forefront internationally. The project includes a consortium consisting of end users and technology developers who will bring the new knowledge and these skills to industrial use. The end product is a finished industrial system aimed at the sheet metal industry.

Facts

• The Innovation Fund's investment: DKK 9 million. DKK
• Total budget: DKK 13.5 million. DKK
• Duration: 3 years
• Official title: Flexible Laser Integrated Production, FLIP

The partners (Consortium)

• Aalborg University
• Migatronic
• Shape Automation
• Micronix
• IPU
• Grundfos
• Jydsk Plate Processing Center
• Envision Energy
• COVI Precision
• JKF Industry