
RESilient and RESource efficient net shapemanufacture of large/complex added value parts by AdditiveManufacturing using powder bed fusion laser beam
The manufacturing industry in Europe produces approximately 230 million tons of waste annually, accounting for 10.7% of the total waste, according to EUROSTAT. Conventional manufacturing methods for large, high-duty industrial components often result in substantial material waste and CO2 emissions. The RES2AM project aims to address these challenges by developing sustainable and resilient additive manufacturing methods for producing large and complex metallic components using Powder Bed Fusion – Laser Beam (PBF-LB). By prioritizing “first-time-right” production, RES2AM seeks to achieve a 50% reduction in both material waste and energy consumption, paving the way for a more efficient and environmentally friendly manufacturing paradigm.
RES2AM addresses critical challenges in the production of large components, such as thermal stresses, process stability, and material handling. The project sets a benchmark for future sustainable manufacturing, particularly in the aerospace and energy sectors, where high-quality and high-performance components are essential. By integrating advanced solutions like real-time monitoring and digital platforms for process control, RES2AM aims to reduce defect levels while enhancing supply chain resilience.
In stage 1, RES2AM focuses on developing and validating pilot systems, including design frameworks, thermal management, and real-time monitoring. These solutions will be tested in industrial environments to ensure their effectiveness and relevance. The demonstrator after full implementation aims to achieve technology readiness levels (TRL) suitable for industrial applications, contributing to a robust and circular manufacturing model.
With the support of leading research institutes like RISE and Chalmers University of Technology, along with industrial partners, RES2AM combines cutting-edge research and innovation with industrial expertise. The project also has a broader impact by strengthening Sweden’s competitiveness and contributing to a more sustainable global manufacturing industry.
The vision of RES2AM is to set a new standard for additive manufacturing, where resource efficiency and sustainability align with high-quality production. By addressing technical, economic, and environmental aspects, the project creates a future-proof manufacturing platform with global applicability.