Manufacturing Processes Group

The group for Manufacturing Processes and Energy Efficiency investigates the use of one or more physical mechanisms to transform a material’s shape and/or form towards the manufacturing a final part. In particular, the following thematic areas are regarded as research topics. Each one of them engages a variety of technologies and workflows. The group deals with Research & Innovation, as well as with technology development.

One of the key research areas of the group is the development and optimisation of advanced manufacturing processes. These include optimisation of conventional manufacturing processes (such as cryogenic machining, machining with robots, welding and roll forming), as well as development and optimisation of non-conventional manufacturing processes, such as Additive Manufacturing, Hybrid Manufacturing, laser welding and cold spray.

Manufacturing Process Monitoring is one additional area that is investigated by the group. This area is relevant in cases of evaluating the status of a manufacturing process; A major part of the research is pertaining to quality, but also other performance indicators can be engaged, such as sustainability. An example of platform facilitating automated quality monitoring can be found here. The choice of sensors is crucial, as it can take advantage of the nature of the process, but also any potential side-effects, while correlation with various performance indicators of the products themselves is also conducted. The AI methods utilized are differentiated per application; indicatively, machine learning, deep learning and other methods such as Hidden Markov Models are mentioned herein as areas of interest. The main challenges pertaining to monitoring issues are reliable performance and data value, security and interoperability issues, sensors’ systems’ design and installation, signal retrieval and storage, as well as the feedback to the machine (in terms of guidelines or as process control). Finally, the link to the so-called digital twin is also addressed, affecting monitoring and modelling, but also process control.

LMS has high expertise in modelling and simulation for manufacturing processes. Building a basis for this expertise starts from the knowledge and understanding of the existing state of the art. Our specialization lies in advanced manufacturing processes, including Additive Manufacturing, using both existing commercial simulation software, as well as custom in-house developed models, solvers and simulation tools. We focus our efforts on tackling important issues that hinder the industrial application of advanced manufacturing processes, striving to address today’s literature gaps. Theoretical (analytical, and numerical), as well as empirical modelling and simulation approaches are in the area of specialization of LMS, including novel applications like digital twins and I4.0, and I5.0 related subjects.

LMS has been working on improving the energy efficiency at different manufacturing levels,  process, machine tool or production level, along the lines of reduce energy consumption towards reducing the environmental impact of manufacturing sector.  LMS has calculated the environmental impact of material removal processes, additive manufacturing and welding  processes. Life cycle assessment  (LCA) was used, not only for the manufacturing sector, but also the construction sector. Technologies and approaches have also been developed including Dematerialisation, Zero Defect via modelling, tracking and monitoring the production, and Circular Economy via innovative technologies and applications in assembly and disassembly lines via a process decision system.

LMS has been  incorporating human-centricity in technologies and product design, but also training.  LMS has been involved in creating and delivering training regarding the uptake of novel manufacturing technology, such as Additive Manufacturing, and raising awareness in digitalisation and sustainability. LMS has pioneered the Teaching Factory paradigm, bringing the factory in the classroom and the classroom to the factory through a remote collaboration scheme. This paradigm has been successfully extended to a network level and utilised towards industrial training and upskilling. The learning factory concept was used to identify the gaps in current education and develop systematic approaches for topics such as circularity.