Imaging expert Framos is currently developing a cutting-edge vision system for Borealis, a Horizon 2020 project aiming to build the largest additive manufacturing machine ever made. The system will combine mechatronics, and subtractive and additive laser processing.
The Borealis machine's sensor system comprises a new camera line, firmware and pattern projector devices, as well as a stereo camera system with FPGA processing and other additional features. A thermal camera and a 3D vision system will acquire thermally enriched 3D scenarios to determine quality parameters for the laser beam and powder deposition. An FPGA provides the system with capabilities for processing most of the captured image data directly on the camera itself. Framos’ sensing system will be used to a perform closed-loop monitoring of the process to give products that require no further machining.
Borealis is due to be complete by the end of 2017. The project intends to make a manufacturing cell that uses 40 per cent less energy, 75 per cent less material, and removes the need for final machining. The finished design will see ablation technology complementing an additive manufacturing fabrication process to allow surface finishing, micro texturing and micro holes that would be otherwise be unfeasible in a single processing step.
Borealis will offer a throughput rate of 2,000cm3/h and sub-micron rugosity surface quality through the combination of a CW laser, a pulsed laser and a fast scanning head. A pilot-scale AM plant prototype as a fully integrated solution for improving 3D manufacturing will be made.
