Europe is the world’s largest manufacturer of machine tools but this position is threatened due to the emergence of Asian countries. However, Europe has world-class capabilities in the manufacture of high-value parts for such competitive sectors like aerospace & automotive and this has led to the creation of a high-technology, high-skill industry. European machine tool builders, part manufacturers and other agents have to work together to increase the competitiveness of European manufacturing industry. Simulation tools are currently a key complement to European machine tool industry expertise but new integrated approaches are needed. The main objective of Twin-Control is the development of a simulation and control system that integrates the different aspects that affect machine tool and machining performance. This holistic approach will allow a better estimation of machining performance than single featured simulation packages, including lifecycle concepts like energy consumption and end-life of components. This integrated concept will also enhance the necessary collaboration between machine tool builders and part manufacturers. The specific industrial objectives are: • Getting machines that work as designed faster (10% reduction) • Getting production processes that work as planned faster (20% reduction) • To get a first-time-right part manufacturing (75%) • To increase production time trough model-based control (increase of 1-2%) • To reduce energy consumption (25-50%) • Improve machine reliability and increase machine up-time due to a proactive maintenance (2-4.5%) All these will contribute to reduce machine tool life cycle costs (15 %) with a reduction of O&M costs in the range of 25%. The project considers the validation and demonstrator in real production scenarios in aerospace and automotive industries. Added to this, 3 demonstrators will be set-up in three pilot lines for spreading results beyond the project end

From aeronautics to oil&gas, complex metal parts embrace major challenges across their lifecycles from the green field intensive manufacturing to the numerous maintenance and repairing operations worldwide distributed. The synergic combination of additive and subtractive processes could overcome individual shortcomings, going beyond the simple succession of steps. 'Plug and produce' modular approach is a key factor to success for such hybridization. In this scenario, 4D will deliver 4 disruptive breakthroughs: • A set of four elementary modules specifically designed for AM that embed the control and monitoring systems which can be integrated on new or existing concepts of machines and robots to realize different processes ranging from the DED (powder and wire) to ablation and cold spray; • A new concept of CNC, constituting a high level sw layer which can be integrated on the top of commercial CNCs, and it is conceived as open to embed portions of the 4D modules control; • A validated process model to fully exploit the synergistic interactions among elementary processes; • A dedicated 4D Engineering CAD/CAE/CAM Platform, which covers the lifecycle of the reference product family where multiple processes and hybrid resources are integrated for the (re)manufacturing stage. Innovation will be physically demonstrated at three possible levels of hybridization: • Modules - Small hybrid modules, integrated on new special machines, focusing on portable units for certified in-situ repair operations; • Hybrid Machines – Hybridization on existing robots and machines; • Production lines - Hybridization of a flexible production line focusing on new concepts for AM mass production. Potential impact: >30% lifecycle cost reduction, unprecedented possibility to customise process applications by combining several processes on several different machines, concrete business perspective supported by detailed business plan with deep market and cost analysis: payback 3y ROI>20%

InterQ project proposes a new generation of digital solutions based on intelligent systems, hybrid digital twins and AI-driven optimization tools to assure the quality in smart factories in a holistic manner, including process, product and data (PPD quality). The broad vision of InterQ project will allow controlling the quality of a smart manufacturing environment in an end-to-end approach by means of a PPD quality hallmark stored in a distributed ledger. The concepts of InterQ will be applied in three high-added value industrial applications. The main objective of InterQ project is to measure, predict and control the quality of the manufactured products, manufacturing processes and gathered data to assure Zero-Defect-Manufacturing by means of AI-driven tools powered with meaningful and reliable data. The project develops five modules: 1) Thanks to the InterQ PPD quality hallmark, the quality of the process, product and data are interlinked, integrated and time stamped. A hallmark will be created after each stage, and the quality will be traced across the supply chain. A trusted framework will be implemented using distributed ledger (InterQ-TrustedFramework module) to exchange quality information. 2) The InterQ-Process module of the project will obtain more meaningful process data for quality optimization. This data will be obtained using new sensors close to the tool and by AI-driven virtual sensors. 3) The project presents new solutions (InterQ-Product module) to predict the final quality of the processes using digital twins fed by experimental data and new digital sensors to measure the product quality. 4) The reliability of data will be checked in two layers: in real time and based on historical and statistical analysis of the data streams (InterQ-Data module). 5) Finally, InterQ-ZeroDefect module will use the reliable information about the process and product quality to improve the production for Zero-Defect-Manufacturing by means of AI-driven applications.