<< Background >>Kilometro Rosso Innovation District together with EOS, Mälardalen University, Letterkenny Institute of Technology, AITTP and ITS Aerospazio Puglia decided to apply for the project AM-TE@CH with the AIM TO PROVIDE AN EFFECTIVE TRAINING METHOD WHICH WILL ENABLE C-VET TRAINERS TO DEVELOP SPECIFIC COMPETENCES IN THE FIELD OF ADDITIVE MANUFACTURING FOR THE MANUFACTURING SECTOR.Additive Manufacturing (AM), the industrial production name for 3D printing, is a computer-controlled process that creates three-dimensional objects by depositing materials, usually in layers. 3D printing is well-known as it allows for rapid prototyping. AM is considered one of the keys enabling technologies for Industry 4.0. It facilitates agile production, and it is a promising solution for the increasing new trend of flexible manufacturing processes (for mass product customization). However, the industrial introduction of AM in SMEs is hampered by a profound skills mismatch, ranging from the selection of the right technology to the design needed for AM components, the selection of parts to be produced, and how to use AM tools. The skill mismatch is partly since the technology is constantly improving, especially in the field of additive processes and production. However, based on the experience of the consortium in the sector, while the educational offer is rapidly evolving in the higher education context, also related to research achievements, it is lagging in vocational training. In this context AM-TE@CH wants to address the following needs:•SMEs skills mismatch in the field of AM;•SMEs preparedness toward digital transformation;•manufacturing employee’s readiness to adopt new production techniques; •trainers’ competences development;•continuous vocational education and training offer in the field of AM.Specifically, the project targets C-VET trainers and the final beneficiaries of the learning experience, i.e. project managers, process engineers, designers, and buyers operating in the manufacturing sector. As it is conceived, AM-TE@CH wants to address their needs in:•Navigating the complex, multivariate landscape of AM equipment, materials, and applications;•Evaluating the business case for transitioning a product to be made using AM versus a conventional approach, either in part or in a whole;•Identifying how, when and where AM can create value across the entire product lifecycle; •Understanding the technical principles and workflows for AM of polymers, metals, and composites.AM TE@CH learning goals address the above-mentioned profiles since it brings knowledge on the AM innovative technology and on the related advantages in the product and processes.<< Objectives >>AM-TE@CH aims to provide trainers in Continuous Vocational Education (C-VET) with a training method and tools to BOOST COMPETENCES’ ATTAINMENT IN THE FIELD OF ADDITIVE MANUFACTURING (AM), not only for trainers but also for the final beneficiaries of the learning experience, i.e. managers, buyers, designer, process engineers operating in the manufacturing sector.In particular the project wants to: •Provide C-VET trainers with competence assessment to understand the learners’ level and then personalise the learning experience so to promote engagement, reflective practice, critical thinking, and skill acquisition;•Provide SMEs with the right tools for workers retention and skills attainment in cutting-edge technology, through the development of training contents which will be generated by the shared experience of leading european organisation operating with AM;•Give access to C-VET trainers to technical yet comprehensive open educational resources, based on a modular and user-friendly structure that can be adapted to different training practices and focused on AM for manufacturing sector. C- VET trainers are often regular employees with occupational responsibilities, as well as responsibilities to train and support learners during their learning experience. Consequently, AM-TE@CH is designed to support continuing professional development, with the objective to: • DELIVER HIGH-QUALITY TRAINING; • FOSTER TECHNICAL AND DIGITAL SKILLS;• WORK WITH DIGITAL LEARNING TOOLS IN DIVERSE AND MULTICULTURAL ENVIRONMENTS.To this end, the workers’ competence levels will be assessed before the learning experience so to personalise the training path. The training contents will be delivered in the form of webinars, learning pills and demonstration videos. A guide for trainers will be delivered on how to use the learning platform and organise the learning experience in a way that is flexible to the levels of the learners while addressing all the aspects related to the adoption of AM techniques. The project aims to achieve a stable transnational cooperation among the partners and their stakeholders’ network. The partners are representative of the knowledge triangle (University, Businesses, Vocational Organisation) with different area of contribution such as: 1Vocational Education and training institutions, for their expertise in recognising strengths and weaknesses of the trainers, and in the learning challenges trainers may face for the high-level skills development.2Companies’ clusters/representative, for their network of SMEs where to address awareness on the potential of AM and collect needs.3AM technology specialists, for their knowledge on this technology. In summary, the complementary skills is fundamental to deliver, in an effective way, high-quality content for a variety of training path as required in AM-TE@CH.<< Implementation >>AM-TE@CH will implement two different types of activities: 1Awareness-raising;2Results-oriented.The first is characterised by the constant effort of the partners to develop a culture of AM both for vocational education organisations and SMEs of the manufacturing sector. To implement this activity partners will:•establish a solid communication strategy not only through their own communication channels but also exploiting their networks;•bring the project message and the best practices collected during project implementation at local, national, and European level, also connecting with existing initiatives on AM;•communicate at large scale AM opportunities trying to bridge the gap between the technology and the final users.The second range of activities is designed to create an integrated training path that can best introduce additive manufacturing technologies in the manufacturing sector.The project’s framework stands on 3 Results that will be achieved following a progression of interconnected activities. 1)BUILD A COMMON UNDERSTANDING ON AM FOR TRAINERS AND SMEs OF THE MANUFACTURING SECTOR•Set up the tools to build a competences’ assessment methodology for trainers;•Involve trainers in the co-creation of the methodology listening to their needs and of their learners.2)DEVELOP HIGH-TECHNICAL TRAINING CONTENTS WITH A COMPREHENSIVE APPROACH•Partners will share their competences to develop a training programme for trainers;•Creation of open educational resources.3)VALIDATION OF TRAINING TOOLS•Trainers will be involved in a pilot test activity together with their learners so to validate training tools;•Partners will assess the results of the pilot.<< Results >>RESULT 1 COMPETENCES’ ASSESSMENT METHODOLOGYThe first result aims to draft a methodology that trainers can use to assess the workers' competences levels. Before the training starts, trainers will be provided with tools (interview/questionnaire templates) that can be used to understand the level of the learners. In this way, they will be able to tailor the training experience accordingly. The tools can eventually also be used for employee’s self-assessment to address the selection of the right training for the development of a certain skill and raise awareness on related opportunities.RESULT 2 TRAINING COURSE CONTENTS AND TOOLSThe set of tools for the learning path will be the following:•The training plan describing the learning outcomes divided in knowledge, skills and competences using ECVET standards;• The training programme divided in units of learning outcomes and described in details in the syllabus;•The learning objects such as modules, videos, webinars, contents presentation and project works.The learning path will be conceived with a modular approach addressing at least the following topics:1.Introduction to AM and its added value;2.Development and production with AM;3.Fundamental of the production process;4.Design for AM;5.Components selection;6.Data preparation;7.Job preparation;8.Operation of a 3D printing machine for Metal and for Polymers;9.Work safety.RESULT 3 “HOW TO” GUIDEThe last result is an “How to” guide addressing those trainers in charge of contents delivery with the aim to facilitate their organisation and the planning of the activities.OUTCOMES•Improve trainers’ digital competences;•Raise awareness on vocational training sector about Additive Manufacturing education and how can meet job market requirements;•Provide SMEs with the right competences for the implementation of an agile production strategy;•Improve VET educational offer;•Create a model of cooperation between Academia, SMEs, Businesses representative and VET.

<< Background >>A range of adversities resulted from covid 19 while several sectors had to figure out innovative means to tackle the difficulties and consequently evolve (including education sector). Nevertheless, covid 19 boosted the educational transition to the digital educational era, on which AREOLA project is focused. AREOLA arises to fight the latest setbacks in VET training. The development of online training materials, and virtual training tools (Virtual Reality – VR and Augmented Reality – AR) is foreseen as an innovative measure to boost VET systems through the new digital era. Additive Manufacturing (AM) is an emerging technology and one of the latest manufacturing trends that could help the recovery of several sectors including the Aerospace sector, which was one of the sectors most affected by covid 19. This sector relies on strategic developments to support its recovery, and the improvement of the supporting technologies is strong pillar of the sector recovery. Metal Additive Manufacturing (AM) Powder Bed Fusion – Laser Beam (PBF-LB) is an AM technology with significant impact in the Aerospace sector. Recently, there were some major improvements within the AM educational sector with the development of an International Additive Manufacturing Qualification System (IAMQS) – managed by AREOLA partner EWF. This system englobes a series of harmonized AM qualifications, on which is included a qualification for PBF-LB Operators with increasing applicability in the Aerospace sector. This qualification will be used as the centre of AREOLA project developments.Through a close connection with AM industrial networks and the Aerospace sector, the AREOLA project will increase the quality of the training provided in the PBF-LB Operators field, ensuring that the high-quality standards in terms of training for this sector are met. Not only the Aerospace sector needs, AREOLA will also tackle the needs in AM training in terms of more inclusive, digital, green and remote training. Besides that, the fact that the practical training can be delivered in a virtual digital environment will significantly reduce the cost of training in European VET providers and will promote the overall VET attractiveness.AREOLA project will pave the path for future developments in AM educational systems (and other manufacturing areas) towards the digital educational area.<< Objectives >>AREOLA project will enable AM VET centres to provide a more comprehensive training in PBF-LB Operator field, with the use of digital training resources. AREOLA will boost AM training sector towards the new digital educational era, with the development of online theoretical training materials and the development of Augmented Reality and Virtual Reality digital tools. The development of these tools will reduce the costs associated to PBF-LB practical training. Besides that, covid 19 adversities will be tackled via an innovative Blended learning path and supporting training tools for AM PBF-LB Operators VET training, which will allow training to be conducted both remotely and on-site. Quality training will be assured through the close relationship with AM Networks and industry, namely Aerospace. AREOLA will support the recovery of the Aerospace, ensuring training excellence in the field, with support of innovative virtual training environments. Taking in consideration the high standards of the Aerospace sector with development of PBF-LB Operator training tools aligned with industrial needs, raising the overall training quality.AREOLA will foster IAMQS implementation, extending its activities in the Aerospace sector. The project will also boost the visibility of AM PBF-LB Operator qualification visibility in EU manufacturing sectors, through excellence in training provided. Raising VET attractiveness will be one of the project main objectives<< Implementation >>During the implementation of AREOLA there are 5 Project Results (PRs), which comprise the work to be developed during project implementation, each PR including a set of tasks associated.In order to achieve the expected results, a series of activities will be implemented. Starting by a research and analysis of requisites and needs in the field of VR and AR training for PBF-LB Operators and the Aerospace field, followed by the development of innovative remote and virtual training tools and Blended learning guidelines. The developments resulted from the afore mentioned activities will be validated through pilot Learning Activities and actualized accordingly to the activities’ results.Additionally, during the project, the following activities will be implemented, including: A learning activity aiming at trainers and other VET staff (inside AREOLA partnership) to transfer knowledge on how to implement the digital training tools developed within the project.Piloting the digital training materials and tools developed in the project together with students and a 4 Virtual Roundtables to discuss on improvements to the content developed, based on pilot results.Furthermore, several dissemination activities will be implemented such as:4 National Conferences for the promotion of AREOLA results and engagement with national key stakeholders 1 European Final Conference for the promotion of the project results and engagement with key stakeholders from 30 EU Countries.<< Results >>AREOLA will contribute to the European digitalisation strategy by supporting the uptake of innovative approaches and digital technologies in the education sector.Moreover, AREOLA project’s expected results are fully aligned with the New Skills Agenda for Sustainable, competitiveness, social Fairness and resilience actions, namely concerning innovative practices in a digital era, transparency and promotion of upskilling / reskilling pathways trough the development of: - Report on analysis of VET and AM industry needs in terms of VR and AR training in PBF-LB Operators- Innovative online theoretical training for PBF-LB Operators, tailored for the Aerospace sector- Virtual and Augmented reality training tools for PBF-LB Operators with the use of a comprised database of Aerospace practical scenarios- Analysis of the applicability of different training strategies (blended and on-site) in the field of PBF-LB Operators- Blended learning guideline for PBF-LB training.

The aim of DREAM is to significantly improve the performances of laser Powder Bed Fusion (PBF) of titanium, aluminium and steel components in terms of speed, costs, material use and reliability, also using a LCA/LCC approach, whilst producing work pieces with controlled and significantly increased fatigue life, as well with higher strength-to-weight ratios. DREAM targets the development of a competitive supply chain to increase the productivity of laser-based AM and to bring it a significant step further towards larger scale industrial manufacturing. In order to upscale the results and to reach an industrial relevant level of productivity, the project is focused on the following four main challenges (i) Part modeling and topology optimization (ii) Raw material optimization to avoid powder contamination (iii) Process optimization, including innovations of the control software of the AM machine, to enable high throughput production (iv) Setup of laser-PBF of nanostructured Titanium alloys with unchanged granulometric dimension for an additional push to higher productivity, since nanostructured metal powders can be sintered with lower energy input and faster speed. The project, thanks to the three end-users involved, is focused on components for prosthetic, automotive and moulding applications to optimize the procedure for three different materials, respectively titanium, aluminium and steel.

The overall aim of the InShaPe project is to develop and demonstrate in four different industrial use cases (aerospace, energy, space and industrial goods) a novel first-time-right Powder Bed Fusion Process of Metals using Laser Beam (PBF-LB/M). The process will be underpinned by two technical innovations: (i) a first-of-a-kind AI-enhanced optical beam shaping module that enables the flexible adaptation of laser beam shapes tailored to the material/geometry of the printed parts; and (ii) a novel multispectral in-line process monitoring and control system application. It is expected that InShaPe will disrupt the manufacturing sector by helping to turn PBF-LB/M from a niche high-potential technology into a mainstream manufacturing technology outperforming traditional methods such as die casting when it comes to the precision of manufacturing parts, treatment of novel super-materials and sustainability. At the same time the InShaPe innovation is expected to keep pace with traditional manufacturing methods when it comes to cost-per-part economics and agile and large-scale production volumes. The KPIs to be reached in the project are: 7 times higher build rate, over 50% lower cost, 60% less energy use and 30% less scrap as compared to current best-in-class PBF-LB/M. Furthermore, the project will demonstrate how AI-based solutions can be practically deployed to deliver advanced manufacturing strategies whilst complying with current ethical standards and user expectations. InShaPe is targeting the rapidly growing global metal fusion additive manufacturing market which is estimated to be worth EUR 6.92 billion annually. In terms of the long-term impact, the successful deployment of the InShaPe technologies is expected to reinforce the European PBF-LB/M manufacturing sector's international reputation as a leading supplier of highly complex parts, and help stakeholders set new best-in-class standards for digital, green, and agile laser-based production methods.