Projects

Shaping Innovations for a Sustainable Future

Conify’s Involvement:

In imPURE project a modular moulding system has been developed to help reduce the cost and enhance the product quality while allowing for fast IM line repurposing through the replacement of interchangeable core and cavity inserts. The idea is to provide a methodology for rapidly aligning needs in medical supply equipment in times of emergency such as COVID-19.

CONIFY employed its wire-based Directed Energy Deposition technology, using a 1.2kW 6-laser system from MELTIO, known for its time and cost-effective production capabilities to produce mould inserts for a finger pulse oximeter. A two-step process which combines additive and subtractive manufacturing is deemed necessary for tooling applications when utilizing wire-DED technique to obtain near-net-shape metallic parts with required tolerances (dimensional and surface finishing). In terms of production time needed, 9 hours of printing time were needed in average for producing each oximeter insert, while PBF technique requires several days, but offers the advantage of producing intricate designs with reduced post-processing needs. Stainless steel 420 wire material cost is another key-factor for assessing cost efficiency of the processes, where the cost for powder is at least 5-8 times higher in comparison to the corresponding wire feedstock (depending on supplier and ordered quantity, availability).


Conify’s Approach

CONIFY undertook the metal AM powder procurement and supply management, by mapping existing preparedness and response capacity of global powder supply chain in order to identify the most suitable procurement options in terms of quality/cost benefit and availability, and establish an agile and responsive powder supply chain from EU powder producers and atomization plants. Powder procurement was based on quality-cost-availability criteria, by efficient screening and characterizing samples from different suppliers and holistic quality analysis to ensure high- quality for AM materials & component manufacturing according to the requirements set from the end-users. Additionally, CONI employed in-house dedicated powder refurbishment & recycling protocols and facilities to recycle and rejuvenate un-fused metal powders from AM machine owners to restore virgin-quality properties and provide an alternative route for material supply.


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Conify’s Publications

Article in MDPI – Metals Journal:

Project Main Results

Conify’s Involvement:

NanoMECommons will establish a transnational and multidisciplinary research and innovation network to tackle the problem of nanomechanical materials characterisation in multiple industries. The focus of NanoMECommons is to employ innovative nano-scale mechanical testing procedures in real industrial environments, by developing harmonised and widely accepted characterisation methods, with reduced measurement discrepancy, and improved interoperability and traceability of data. To achieve this goal, NanoMECommons will offer protocols for multi-technique, multi-scale characterisations of mechanical properties in a range of industrially relevant sectors, together with novel tools for data sharing and wider applicability across NMBP domain: reference materials, specific ontologies and standardised data documentation.


Conify’s Approach:

Digitized material, structure development, printing and part performance database.

Material

Duplex/Super Duplex SS and their powder blends with SS 316L, SS420, H13, P20, PH17-4 SS.
Chemical composition CONI’s in-house powder characterization protocols (based on ASTM/ISO)

Process

Tune/modify microstructure through the process settings and thermal treatment. Energy density, cooling rate and reheating phenomena.

Performance

Phase-separated physical and mechanical properties. Residual stresses induced from rapid solidification conditions/reheating phenomena during printing


Conify’s Publications

Article in MDPI – Metals Journal

AMAC+

AMAC+ is an EU cooperation project between 3D-Components, Norway and Conify, that seeks to establish additive manufacturing (AM) value-chain for aerospace components. The project encompasses numerical analyses, material selection, processing, finishing, and quality control. The aim is to evaluate costs and compare AM with conventional manufacturing, while testing and validating modern designs and materials. The project has the potential to transform the aerospace industry by introducing an efficient and sustainable process towards reducing waste and environmental impacts, improving performance, and lowering costs.

Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European innovation Council and SMEs Executive Agency (EISMEA). Neither the European Union nor the granting authority can be held responsible for them.