The new emerging generation of microsystems represents a major opportunity for a substantial EU economic growth, in an industry counting already more than 200.000 workers and a turnover in 2019 of €450 billion. The Mesomorph concept provides the means to overcome the following 4 main hurdles: 1. The intrinsic physic of microsystems doesn’t allow the simple downsizing of conventional technologies to industrialize micromanufacturing processes. Mesomorphallows to limit the number of micromanipulation tasks by integrating an all-in-onemachine featuring novel processes for the direct creation of functions (electronic, fluidic, optic) directly on a substrate, with a RESOLUTION down to 300nm, by combining multi-material addition (Two-Photon Polymerization, Atomic Layer 3D nano printing) and subtraction (Femtolaser micro-ablation) in a self-contained white room. 2. Because of the intrinsic slowness of physical processes at microscale, productivity cannot be achieved by sequencing multiple single steps. Mesomorph proposes a scaleup throughput by PARALLELIZATION and batch processing UP TO 50k PARTS/YEAR, leveraging a new multiple micronozzles system to extend the SADALP working area from 10x10mm up to 500x500mm, and concurrently leveraging on the beam splitting technique of a high-power fs laser for ablation. 3. Microsystems cannot be conceived with subcomponents. Mesomorph includes a specific Design-to-Lifevalue Platform to guide the development of new microsystems by fully exploiting the new processes. 4. Innovation cannot be limited by the financial risk associated with the necessary investments. Mesomorph implements a new “Manufacturing as a Service” business model in which all the value chain’s actors can benefit from a positive net cash flow since production's start, effectively removing entry barriers for innovators. Mesomorph consortium is composed of 13 partners from 5 different countries. Each partner represents excellence in its own field.

Fluently leverages the latest advancements in AI-driven decision-making process to achieve true social collaboration between humans and machines while matching extremely dynamic manufacturing contexts. The project results will be: 1) Fluently Smart Interface unit and 2) the Robo-Gym. The Fluently Smart Interface unit features: 1) interpretation of speech content, speech tone and gestures, automatically translated into robot instructions, making industrial robots accessible to any skill profile; 2) assessment of the operator’s state through a dedicated sensors’ infrastructure that complements a persistent context awareness to enrich an AI-based behavioural framework in charge of triggering the generation of specific robot strategies; 3) modelling products and production changes in a way they could be recognized, interpreted and matched by robots in cooperation with humans. Robots equipped with Fluently will constantly embrace humans’ physical and cognitive loads, but will also learn and build experience with their human teammates to establish a manufacturing practise relying upon quality and wellbeing. The bond between human and robot is personalized, and it is established during a preliminary training at the Robo-Gym, the first European hub for human-robot interactive training, where human and robot learn from each other a common work practice. Fluently will be validated by demonstration on three full scale pilots characterized by various level of automation, production dynamism and complexity of the manufacturing decision making process. The total project value required to commercialize the Fluently device and Robo-Gym concept is 18.8 M EUR. Forecast for EBITDA in 2028 is 16.3 M EUR, payback in 2028, with 13% gross profit and ROI 91% in line with sectorial performances. The new turnover generated requires at least 325 workers employed along the Fluently supply chain. Fluently will bring together 21 key industrial and academic stakeholders from 13 countries.

WISE sets a new frontier for product complexity by shifting the focus from geometry to functionality, introducing features such as self-healing, triggered biomolecule diffusion, and smart repairing. This disruption redefines current design methodology, leveraging advanced AI-aided engineering and multi-scale, multi-process manufacturing to achieve unprecedented complexity. WISE has the potential to drive a discontinuity in the growth of the European industry by convincingly demonstrating an innovative, competitive, and scalable manufacturing concept based on a single machine that integrates macroscale processing (i.e., DED via hybrid blue-IR lasers) and micro-nano scale processing (i.e., fs and ns laser ablation, 2PP, DALP). WISE will deliver a TRL7 multi-process machine integrating high-precision, multi-scale techniques for producing complex multifunctional products. The project will demonstrate the machine's performance, flexibility, and precision by producing three complex hybrid products in MedTech, Aerospace, and Power generation sectors. The project builds upon TRL5-validated results from previous H2020 projects, which have brought significant innovations in the field of advanced manufacturing and enabling technologies. The work plan includes a final demonstration to validate the solution through the production of complex components based on end-user requirements. Upon completion, WISE will be further developed to reach TRL9 within 24 months, leading to its commercial launch as a multi-process manufacturing station. The WISE consortium is composed of 16 partners, including 8 SMEs, 4 LE, and 4 RTD. Their expertise covers mechatronics, intelligent nanostructured components, laser-material interaction, high-precision machines and tools. The project partners form a cluster of European countries playing crucial roles in the production of functionalized products with smart functionalities, adaptive photonic solutions, and advanced mechatronic systems.

The AVANGARD project addresses the integration of three novel processing units into an existing Microfactory test bed conceived to produce urban electric vehicles. The units are state of-the-art multipurpose and multifunctional demonstrators on their own, specifically: Robotized integration of laser cutting-shaping-welding for 3D components Supersonic deposition of metallic powders for high speed 3D printing Large volume and high-speed 3D polymeric printing The operation of the AVANGARD pilot will be demonstrated manufacturing I-Bikes, I-CARS and innovative battery packs. The proposed innovations target urban mobility where we are entering an era of rapid transformation and disruption which are also challenging traditional paradigms on manufacturing and business models characterized by an unprecedented speed, scale and scope of technological change. The project will prepare the environment for novel forms of collaborative distributed manufacturing amongst different EU regions. Innovative value chains will be pursued to overcome the scale (giga) and speed being established in planned economies (China) with market development controlled by the governments attitudes, targets and policy tools. To manage the IPRs and the supply chain, AVANGARD will implement a hybrid public-private Blockchain platform where the public chain increases security through distributed consensus and validation and the private sidechain increases speed while keeping sensible data stored in the facilities of partners. The platform will allow auditability of sources, traceability, verification of sources, still with private control of documentation and compliance to data retention policies. The theme of Blockchain-powered manufacturing is relatively new. AVANGARD will address it with Ideas Forward PC, an SME that runs specialized BC tech commercialization projects.

WAVETAILOR focuses two industrial scenarios which are related to the complex multi-material component and assembly. The first one is Directed Energy Deposition of a multimaterial leading edge for a hypersonic hydrogen-driven airplane, while the second relates to the Powder Bed Fusion of complex multi-material assembly of a drone for urban delivery. The challenges in both cases are related with zero-defect manufacturing, sustainability and first-time-right manufacturing. WAVETAILOR aims to solve the high-precision in complex material structure manufacturing, the disassembly, reuse and recycling of components, while reducing the environmental footprint of both manufacturing process and the components itself. To achieve this, three main pillars are developed in the project: 1) flexible energy efficient photonic setup based on modular diode-based laser source and multi-wavelength optics; 2) full reconfigurability of this setup, to use minimal energy and material resources in manufacturing of two use cases and 3) ZDM and ZDW strategies at assembly level controlling the compliability of complex multimaterial products at machine level, shop floor level and delocalized manufacturing chain level. The latter pillar will be based on digital sibling (shop floor level) and twin (cloud level) for automatic assessment of component/assembly design for circularity; first-time right process planning using synthetic legacy data and ZDM/ZDW based on real time process and post-process monitoring. When the WAVETAILOR objectives are achieved, the manufacturing process of the two use cases will have spent 200MWh of energy less, 923kg of waste less, while the production costs are going to be 50-65% lower. In order to prove this a dedicated sustainability study is provided along the project.