R&S Project
FLASH
Fused Laser-Assisted Shells for High-performance Structures — Additive manufacturing for composites
Project Objective
The FLASH project aims to develop a new manufacturing paradigm for the realization of large-scale carbon fiber structural components with high aesthetic and functional value. Through additive manufacturing of metallic materials, the project intends to overcome the limitations of current production methods, reducing costs by up to 25% while maintaining and improving aesthetic and functional quality.
Innovative Technology
FLASH uses additive manufacturing to create functionalized metal shells that:
Smart Molds
Metal shells obtained from additive technologies that replicate the final composite shape with precision.
Dimensional Stability
Ferromagnetic materials with low thermal expansion coefficient to minimize processing distortions.
Controllable Finish
Optimized surfaces with texture, precise tolerances and high aesthetic quality for high-value composites.
Cost Reduction
Potential production cost reduction of up to 25% compared to traditional methods.
Process Solutions
The project develops methodologies based on:
- Metallic Additive Manufacturing: Use of metal wire and laser (WAAM, advanced technologies)
- Adaptive Control: Real-time correction systems for precise geometries
- Thermal Management: Dynamic cooling and support systems during construction
- Digital Twins: 3D models for validation and shape control during construction
- Reactive Disassembly: Detachable and machinable components for complex assemblies
- Sensors and Monitoring: Real-time thermal and geometric data acquisition
Impact and Applications
The FLASH project brings innovation to high value-added sectors:
- Large-scale aerospace and structural components
- Industrial products with highest aesthetic standards
- Custom solutions for high-tech applications
- Production sustainability through waste reduction and recycling
- Scalability of series production while maintaining quality and precision
Objectives and Expected Results
The project proposes to achieve:
- A pre-industrial prototype demonstrating all process innovations developed
- Feasibility of ferromagnetic metal shell production with additive manufacturing
- Scalability for production of large-scale carbon fiber structural components (> 1 m²)
- High aesthetic degree certified and validated (TRL6 — pre-industrial level)
Project funded by POR FESR Veneto Region
Intelligent Specialization Strategy (S3)
Intelligent Specialization Strategy (S3)