Digitalization of Metal Manufacturing Processes through Focused Energy
Context and Objectives
The DIGIFUS 4.0 – Phase 2 project drives the advanced digitalization of metal additive manufacturing processes to improve energy efficiency and reduce material consumption. Its goal is to develop a digital twin capable of simulating
and controlling focused-energy metal deposition processes in real time, facilitating automation and sustainability.
The project is promoted by AERA and the Aragon Automotive and Mobility Cluster (CAAR), in collaboration with ALOT METAL, S.L., GALA GAR, S.L., and the Aragon Technological Institute (ITAINNOVA). This partnership enables the transfer of technological knowledge to the Aragonese industrial fabric, advancing toward smarter and more competitive manufacturing.
Expected or Achieved Results
In Phase 1, already completed, the WAAM (Wire Arc Additive Manufacturing) process was selected as the experimental base. Thermal behavior of the material was simulated using Abaqus software and validated with real test specimens. The developed models demonstrated high accuracy, serving as a foundation for this second phase.
Phase 2 focuses on thermal and mechanical modeling, studying how successive layers affect the underlying ones. The objective is to identify residual stresses, microstructure defects, and potential deformations to optimize
manufacturing parameters and predict final part quality.
Phase 3 will culminate in the development of a 3D simulation software integrating a full digital twin of the GMA-DED process, providing companies with an advanced tool to plan, monitor, and improve additive manufacturing operations.
Industrial and Environmental Impact
DIGIFUS 4.0 – Phase 2 promotes more flexible, precise, and sustainable manufacturing, aligned with Industry 4.0 and the Sustainable Development Goals (SDGs 7, 8, 9, and 13). Its application will reduce costs, save energy and
materials, and improve traceability and quality of manufactured metal parts.
