Transforming Manufacturing with Real-Time Monitoring: A Caracol AM Success Story
Wire Arc Additive Manufacturing (WAAM)
Caracol AM has significantly improved additive manufacturing (AM) by integrating in-situ monitoring technologies participating in real time within their HERON AM platform. Within the scope of the INTEGRADDE project, they collaborated with AIMEN to optimize its production capabilities, thanks to the creation of a digital twin of the WAAM process.
Use case in a Nutshell
Through the INTEGRADDE Open Pilot Line, AIMEN (host) and Caracol AM (beneficiary) collaborated to integrate an in-situ monitoring system into Caracol’s platform, HERON AM. The goal was to build a digital twin of the WAAM process to enhance quality control and enable future process certification. Caracol tested the solution in an industrial environment, while AIMEN participated to achieve a correct implementation of the developed systems.
About the collaboration partners
Caracol is a Italian company with expertise in advanced additive manufacturing, offering large-scale 3D printing solutions. Using proprietary platforms and robotic systems, Caracol provides end-to-end production services for complex, custom components across industries such as aerospace, automotive, energy, and marine.
AIMEN is an Innovation and Technology Centre highly specialized in materials and in advanced manufacturing technologies, especially joining technologies and laser technologies applied to materials processing, robotics and automation.
Description of the Collaboration
Problem Addressed
Caracol AM aimed to implement a scalable, reliable additive manufacturing process that could meet industrial demands.
Solution
Development and integration of an in-situ monitoring architecture into Caracol’s WAAM system. The monitoring system provided real-time data acquisition, process visualization, and the creation of a digital twin, to avoid defects and to facilitate process certification.
Execution
- Caracol and AIMEN collaborated under the INTEGRADDE Open Pilot Line, part of the WAAM technology suite.
- Caracol adapted its robotic WAAM system, including hardware and software, to integrate AIMEN’s monitoring solution.
- A demonstration part was produced with the monitoring system and digital twin in place.
- The collaboration enabled a successful integration test within a few weeks, validating the digital process control setup.
Host Role (AIMEN)
AIMEN provided the in-situ monitoring system and technical expertise, supporting its integration into Caracol’s platform. For this, AIMEN worked to achieve system compatibility, successful testing and validation.
Beneficiary Role (Caracol)
Caracol adapted its HERON AM system to add AIMEN’s monitoring solution. The company provided the use case, and acquired knowledge in real-time monitoring, digital twins, and finally achieved process certification.
Results of the Colaboration
New business possibilities (aerospace and food)
Enhanced process control and optimization through the use of real-time data
The implementation of a digital twin provided advanced process visualization
Results of the Colaboration
In the case of Caracol, a signal acquisition and visualisation system has been deployed, collecting data during the manufacturing of parts using the WAAM process, which provides detailed inputs of what is thermally happening to the part during manufacture.
We consider the experience beneficial for AIMEN, opening up the range of possibilities for which this tool could be exploited.
Working with the INTEGRADDE team and their technology transformed our manufacturing process. The collaboration between our teams and the readiness of the technology led to a successful integration test and the creation of a digital twin of a demo part, pushing the boundaries of what’s possible in additive manufacturing.
Project info:
The use case is part of Caracol’s involvement in the Horizon 2020 INTEGRADDE project, Grant Agreement noº 820776, aiming to innovate the field of Additive Manufacturing.
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