6.3 Production / manufacturing systems

13_SLM & CS ADDITIVE TECHNOLOGY

The node is comprised of the following key technological systems:

• The SLM 280H device for additive manufacturing using powder metals with a multi-material deposition system – this is a unique extension of SLM technology, extending it with a special deposition system capable of depositing two metal powder materials in a single layer. The device is also equipped with an external filtration system, allowing for work with reactive materials. The machine can be configured to deposit one or two materials horizontally or vertically. This makes it possible to create components with complicated and structured geometry and to combine different material properties.  Parameters: Laser power output 400 W, scanning laser speed 10 m/s, inert gasses argon and nitrogen, argon and helium. Materials: stainless steel, silumins, titanium alloys, copper alloys, magnesium alloys.
• Device for cold kinetic deposition – a unique system utilising the configuration of robots designed for the node, including anti-noise and anti-dust cabins and positioning elements allowing for the deposition of powders on flat, but also curved or rotating planes using a system from the company Impact Innovations. Parameters: Pressure of propellant: up to 50 bar; gas temperature: up to 1100 °C; shielding gas: N2; Powder is deposited into the convergent part of the de Laval nozzle (upstream). Materials: all regularly produced metal powders (pure metals or their alloys, apart from W).
• Laboratories for structural and phase analysis and a mechanical testing laboratory for the study of material properties for the preparation and evaluation of experiments.

14_DED & LPD ADDITIVE TECHNOLOGY

Key technologies:

• Insstek MX 600 is a unique device for multi-material deposition of metal materials (PB – DED), capable of the simultaneous deposition of up to 4 powders. This system has a significantly larger speed of deposition at volume. Large deposition volume of approx. 350 × 450 × 600 mm. 7× larger than common deposition powder bed systems.
• The Aurora Laser Powder Bed (LPB) system – for deposition on metal parts with sensitive resolution. 
• The ability to produce larger components using combined DED and LPB deposition. Deposition of entirely unique materials thanks to the ability to combine powders during deposition and the utilisation of in situ nanoparticle production. 
• A 3D printer for plastic materials – support structures for metal component designs. 
• A unique software analyses package, providing everything needed for the design and achievement of the resulting properties of AM deposited parts (microstructure, fractographic analyses, thermophysical measurements, software for optimisation of component shape, know-how in the area of contour cutting methods for the measurement of residual stresses, mechanical properties characterisation methods and know-how in thermal and thermochemical treatment of metal materials. Software for topological optimisation and further software for the simulation of the internal deposition process using 3D Experience, or using the general FEM package Abaqus.

15_ADDITIVE TECHNOLOGY & SURFACE INTEGRITY

The key technologies of this node include:

• 3D metal printing laboratory with three professional SLM metal printers working on SLM technology with the ability to print a broad range of machine materials – for example 316L steel, aluminium alloy AlSi10Mg, titanium alloy Ti64 ELI, M300 high-strength steel, nickel alloys In625, In718 and cobalt alloy CoCr. Renishaw AM500E (the only device in Europe, currently there are only 3 worldwide), laser power output up to 500 W, construction speed 5 cm³ – 20 cm³ (/h), layer thickness 20–100 µm, maximum work area 250 × 250 × 350 mm. Renishaw AM400 (a unique device for regulating the flow of inert gases in the working chamber is currently in development), laser power output up to 400 W, construction speed 5 cm³ – 20 cm³ (/h), layer thickness 20–100 µm, maximum work area 250 × 250 × 300 mm. Trumpf TruPrint 1000 (a unique depositing machine developed and tested by the team), laser power output up to 200 W, construction speed 2 cm³ – 18 cm³ (/h), layer thickness 10 – 50 µm, maximum work area ø100 × 100 mm.
• 3D plastic printing laboratory – a device based on SLS technology with the ability to print: PA 2022, PA 2202black, PA 3200GF, Alumide, PA 1101, PA 1102 black and ALM PA 640 GSL. Two EOS P369 machines with a uniquely developed structure for moving polymer powder feed bins, laser power output up to 70 W, construction speed up to 6 m/s, layer thickness 60–180 µm, maximum work area 340 x 340 x 600 mm. EOS Formiga P110 Velocis, laser power output 30 W, construction speed up to 5 m/s, layer thickness 60–120 µm, maximum work area 200 × 250 × 330 mm.
• Composite 3D printing laboratory – a device using CFR methods with the ability to print: Onyx, Onyx FR, Nylon, Carbon Fibre, Fiberglass, Kevlar, HSHT Fiberglass. Markforged X7, layer thickness 50 – 250 µm, maximum work area 330 × 270 × 200 mm.
• HIP furnace for heat treatment, maximum pressure 200 MPa, maximum temperature 1500°C, working gas Ar.
• Sophisticated additive manufacturing software – part of the equipment of the 3D laboratories is software designed for use with additive manufacturing, such as: MSC Simufact Additive, Altair Inspire – Topological optimization, 3D Experience – Functional Generative Design, Autodesk Inventor Professional – Generative Design and SOLIDWORKS – Topology, Materialise Magics and Topology.
• The following devices are available for surface integrity testing after manufacturing technologies have been used: The ALICONA Focus G5 non-contact optical scanning sensor device with rotational unit for surface texture analysis and 3D high-definition optical measuring; a device for non-destructive measurement of residual stresses via the magnetoelastic method, a light microscopy laboratory, a device for measuring strength under load and momentum during machining (three-part piezoelectric dynamometer), CNC machining centres.
• A special software package for the prediction of design solutions, analysis of stress-deformation behaviour, structural designs, analysis of geometric data from CAD designs, preparation of data and programs for the control of CNC machine tool, visualisation and verification of machining, control of measurement and metrological devices, analysis and evaluation of measured data and more.
• The internally/origin developed digital twin and process software system “MillVis” was designed for the pre-process control and optimisation of NC programs, machining optimisation strategies and a detailed visualisation of machining results. The virtual cores are from CNC control systems Siemens VNCK, Heidenhain iTNC, MEFI. There is a test laboratory with machines, hardware and software for experimental research into machine-process interactions and for the validation of digital twins.

16_ADVANCED MANUFACTURING SYSTEMS

Node technologies:

• In the area of casting, welding and additive technologies, there is a unique prototype workshop for Mg alloy casting under a protective atmosphere, a workshop for resistance welding using DALEX PMS 11-4, PrimKoM04 with a unique configuration of parallel condensers to regulate casting processes, a robotic workshop with resistance pincers ELMA – VMC_VISION_ROB. There is also a welding shop with a Fanuc Arc Mate 100iC robot, the collaborative robot ABB YuMi, a 3D printing workshop using DMLS Concept Laser M2 and a 5-axis and 3-axis stand / machine for WAAM experiments.
• For machining, quality control and robotic manipulation, there is a set of machines for the machining of difficult-to-machine materials and highly precise production, a workshop for thermal clamping of tools and a workshop for precise machine calibration. Kuka robots for integrated machining manipulation. A quality control and tuning device for CMM Zeiss UPMC Carat, Zeiss Prismo with active scanning system,  computed tomography system Zeiss Metrotom 1500, reference roundness measuring instrument, contour measuring system.
• For surface modification, there is a world-unique ion implanter (ion energy 90 keV / ion stream 10 mA) for non-semiconducting applications in configuration with a coating unit. Hauzer Flexicoat 850 duplex coating device for deposition of layers onto metal materials and plastics using the VPD method, with the option of plasma nitration.

17_MECHATRONICS, SMART COMPONENTS, NVH

Key node technologies:

• Assembly of production testbed 4.0, which facilitates research into the area of complex production machine modelling and the development of applications using artificial intelligence for smart solutions integrated in machinery. This is a set of production devices assembled into a distributed production testbed and is comprised of, among other things, the CNC milling machine MCV 754 QUICK, the CNC lathe SP280SY, a robotic workshop for example for plasma welding, a hydraulic press.
• A collection of unique technologies for increases in production precision, allowing, among others,  the verification of the precise positioning of production machinery. Together, the whole set of machinery allows for the evaluation of model situations for research into volumetric precision on specific machines or using specific technologies. LaserTRACER: resolution 0.001 µm, MPE 0.2 µm + 0.3 µm/m, maximum acceleration 3 m/s², top speed 5 m/min measurement range 0.2 – 15 m. Laser interferometer: resolution 0.001 µm, MPE ±0.5 ppm, top speed 4 m/s, measured range up to 80 m, scan rate 50 kHz. Ballbar: resolution of the sensor 0.1 µm, MPE ±1.25 µm, U(k=2)=0.7 + 0.3L, scan rate 1000 Hz, measured range ± 1 mm.
• Virtual reality centre for visualisation of the developed devices: Virtual CAVE – a projection system making use of passive stereoscopic rear projection, comprised of three vertically-oriented projection screens + a fourth projection surface with direct floor projection. Powerwall – a device intended for the display of three-dimensional digital models within an immersive virtual reality environment using a single projection screen. Headsets for virtual reality.
• Concerning the evaluation of acoustic and vibration characteristics, there is a fully anechoic acoustic chamber, whose configuration is unique within the Czech Republic. The acoustic chamber is sized for the operation of combustion engines, transmission systems and propulsion tract assemblies or self-propelled test assemblies, for the whole range of operational load. The frequency range for technical experiments is within an interval of 100 Hz – 20000 Hz, with a sound absorption coefficient of 0.99.  One supplementary device is the acoustic camera – allowing the localisation of areas of initiation and sound wave propagation. A set of intense acoustic probes for the localisation of noise sources in the lower portion of the frequency spectrum. 
• Uniquely in the Czech Republic in the area of experimental infrastructure for mechatronics and metrology, there is a combination of optical deformation measurement devices, a comprehensive set of analysers (PULSE LAN XI, QuantumX, MGCPlus), impact hammers and vibrating exciters, the dSPACE system and a microscope for surface property observation: Talysurf CCI Lite.

18_PRODUCTION OF NANOFIBRE STRUCTURES

The node includes the following uniquely developed devices:

• Chambered coaxial spinner – laboratory device allowing for the production of coaxial nanofibres using the process of electrostatic spinning (DC electrospinning). This device uses a patented mechanism of flooded spinning from a free surface, which allows the production of coaxial nanofibres with specific functional properties. The unique device can be fitted with various types of spinning electrodes and collectors that significantly influence the production parameters of the device and the variability of nanofibrous layer preparation concerning composition and morphology.
• A production line for the manufacture of composite materials containing nanofibres – this laboratory device allows the manufacture of fibrous products utilising the exceptional properties of nanofibrous materials, which are appropriately combined with the properties of the supporting core. The core, which is regular yarn, multi- or monofilament, ensures the expected tensile strength of the linear material. The core is coated / gimped with nanofibres creating the outer layer of the composite yarn, giving the material its specific properties. Based on its patent, the production line allows for the production of new functionalised nanofibrous core yarns, for example by incorporating biologically active molecules into the yarn casing.
• The chambered membrane spinner (KOMES) allows for the laboratory discontinuous production of flat composite nanofibrous membranes on a nonwoven spun-bond-type carrier textile. The device is capable of uniform dispersal of microparticles (solid or liquid) into inter-fibrous gaps of nanofibrous material, granting the membrane exceptional adsorption properties. This unique method works because particles with a larger specific surface area than nanofibres have all that surface available for adsorption, because they are no immersed in the nanofibres. Nanofibrous material produced by patented technology has a fine mesh structure that ensures microparticles won’t be released from the composite membrane, even when exposed to high-frequency vibration.
• The device for the manufacture of nanofibres using centrifugal spinning can produce nanofibres from polymer solutions or melts using centrifugal forces. This device allows for spinning using cylindrical nozzle-free heads.
• A set of unique devices and equipment for spinning (disc spinning electrode, electrode with integrated polymer solution delivery system, electrode for mixed nanofibrous material production, band electrode for continuous production of flat nanofibrous material, a coaxial electrode for AC spinning of polymer solutions, a spherical spinning electrode, multi-stage spinning electrode, circular coaxial spinning electrode, a spooling device for core nanofibres, etc.).

19_COMPLEX PRODUCTION UNITS

Laboratory and pilot units of the node for complex modelling of modern processes include:

• Mixing devices and reactors. A unique portfolio of variable solutions to mechanical, hydraulic and pneumatic mixing systems in model apparatuses of various geometric configurations from laboratory models to pilot units with volumes of 6–2000 litres. The device allows for the study of the transfer of momentum, heat and mass in the mixed batch, determining and optimising the output characteristics of mixing systems including a kinetic analysis of the process. Development and testing of static mixers is enabled by a one-of-a-kind hydraulic track, which also makes it possible to evaluate the hydraulic characteristics of inserted pipe components and pumps. Dispersion devices such as the colloid mill, stator-rotor mixers with revolutions of up to 25 000 min^-1 make it possible to prepare the groundwork for device design and the preparation of submicron dispersions.
• Hydraulic separation devices. The variable configuration of the laboratory equipment allows for the analysis of separation efficiency for individual dispersion phases based on operational properties and the required output of the technology. Settling devices (lamellar settlers, column apparatuses 10–300 mm in diameter), depth and cake filtration (80–300 mm in diameter), cuvette, filtration and settling centrifuges with a working drum volume up to 5 l, aero- and hydrocyclone scrubbers with variable geometric and operational characteristics. Flotators and electroflotators. Experimental devices that allow for the processing of volumes from tens of ml to the order of lower hundreds of litres.
• Devices for the study of the hydraulic characteristics of equipment. Experimental analysis of flow properties with the goal of predicting the hydraulic behaviour of substances and devices. Variably equipable with column apparatuses with a diameter of 50–200 mm for the testing of the hydraulic characteristics of single or multi-phase flow through porous layers and apparatuses being filled. Devices for the study of the flow of viscoplastic and viscoelastic substances – pipeline tracks with a circular and non-circular cross-section, extrusion.
• Heat exchangers. The process characteristics of heat exchangers (tube, plate and plate-fin) are experimentally analysed using a unique measuring track (cold side – at most 50 m³ h^-1, displacement 40 m, natural liquid temperature; air – at most 42 m³ h^-1, displacement 45 m, temperature 20–90°C, air – natural temperature, flow rate 0–90 m³ h^-1, overpressure 2000 Pa). It is possible to test the hydraulic and heat characteristics of liquid–liquid, liquid–gas and gas–gas heat exchangers, which can then be used to complete the design and optimisation of the shape and size of heat exchange surfaces.
• Evaporators and crystallisers. Experimental elements allowing for the study of the processes taking place during liquid boiling, the design and optimisation of operating conditions concerning effective use of heat during drying and regeneration. Laboratory batch apparatus for the study of liquid boiling (maximum of 400 °C, atmospheric pressure, 1–5 l of liquid). Pilot model of crystallisation evaporator with natural / forced circulation (20 l, 0.6 MPa).
• Driers at a pilot scale provide a base for the experimental study of the statistics and kinetics of drying processes, necessary to increase the size and design of drying devices. Convex chamber dryers (0–5 ms^-1 drying air temperature 20–80°C, chamber volume 0–2 l, sample size up to 0.5 kg). Spray drier (evaporation 0–3.2 kg h^-1, air temperature 20–300°C with a flow rate of 0–100 kg h^-1). Continuous microwave drier (2 kW magnetron, drying area size 0.120 m², belt speed 0–2 m h^-1).
• Absorption and adsorption devices. The pilot-scale laboratory unit is used for the study of process characteristics during absorbent testing, adsorbent separation of the required components of industrial waste gasses. Column apparatuses of absorption units are constructed using DN80 PN6 with a maximum temperature of 130°C, flow rate of 0–6700 Nl h^-1. Column apparatuses of adsorption units in PSA mode are constructed using DN32 PN6 with a maximum temperature of 40°C, flow rate of 0–800 Nl h^-1.
• Membrane separation unit. A unique laboratory unit that allows the analysis of the operational characteristics of polymer membrane modules when separating components from gasses. The unit allows for the preparation of input gas mixtures of any composition containing CO₂, CO, H_2, N₂, O₂, CH₄, H₂S including a universal port for the finished mixture with a maximum flow rate of 200 Nl h^-1, temperature 15–60°C and pressure 10 Mpa.
• Reactors and bioreactors. A broad portfolio of reactors (1–40 l) and bioreactors (1–200 l) at laboratory to pilot plant scale (1–200 l) facilitate the study of simultaneous momentum, heat and mass transfer in multi-phase systems including complex analysis of energy and efficiency demands. Variable universal reactor with duplicate shell, a lower and upper mixing system used mainly in biotechnological applications to produce advanced biofuels.
• Device for the hydrothermal pre-treatment of raw materials. Thermoreactor (maximum batch size 0.5–1.0 l, 40–200°C, 0.1–1.5 MPag, cooling of the heat-treated batch). A device for thermic expansion pre-treatment (5–10 l, 40–200°C, 0.1–1.5 MPag, subsequent sudden decompression of heat-treated batch). Both devices allow the study of the operating conditions and transport characteristics of transfer phenomena during hydrothermal processing of each batch, which can be catalysed by adding weak solutions of acids and bases.
• Crushing and milling device. A multipurpose set of devices allowing for the processing of materials at any humidity or solidity from an initial size of 10 cm to particle sizes at the single micrometre level. An integral part of all units is the analysis of output characteristics and passive resistances. Knife mill (3 kW, 3000 min^-1), ball mill (2–10 l, 80 min^-1), bead mill (1–3 l), colloid mill (3000–15000 min^-1, 1–20 kg h^-1) and unique macerator of our own construction.