Borealis project presents an advanced concept of machine for powder deposition additive manufacturing and ablation processes that integrates 5 AM technologies in a unique solution. The machine is characterized by a redundant structures constituted by a large portal and a small PKM enabling the covering of a large range of working cube and a pattern of ejective nozzles and hybrid laser source targeting a deposition rate of 2000cm3/h with 30 sec set-up times. The machine is enriched with a software infrastructure which enable a persistent monitoring and in line adaptation of the process with zero scraps along with number of energy and resource efficiency optimization policies and harvesting systems which make the proposed solution the less environmental invasive in the current market. Borealis idea results from a consortium composed by the excellence of developers of worldwide recognized laser machines and advanced material processing together with the highly precision and flexible mechatronic designers. These two big clusters decided to join their expertise and focus on new manufacturing challenges coming from complex product machining in the field of aerospace, medtech and automotive represented by major partners in the market. Borealis project targets a TRL 6 and will provide as outcome of three years work two complete Borealis machine in two dimensions – a lab scale machine and a full size machine – which are foreseen to be translated into industrial solution by 2019.

Nanostructured surfaces that engineer the interaction between an object and its surroundings are a subject of scientific and manufacturing importance. Nature routinely creates nanostructured surfaces with fascinating properties, such as antireflective moth eyes, self-cleaning lotus leaves, colourful butterfly wings, and water harvesting desert beetles. Well defined nanostructured surfaces have huge commercial potential due to product enhancement: reduced reflectivity in photonic devices and solar panels, antiglare plastic parts for the automotive industry, hydrophobic self-cleaning surfaces for smart packaging, antireflective and smudge-free smartphone displays, and biofouling resistant marine and water treatment systems. Unfortunately, the lack of cost-effective, scalable, nanopatterning methods is a major hurdle for the commercial exploitation of nanopatterned surfaces. SUN-PILOT will address this challenge by developing a novel and cost effective platform for up-scaling sub-wavelength nanostructures fabrication techniques that can be applied to curved surfaces such as optical lenses, and the mass production of metal moulds for injection moulding of plastic parts. The expected impact of SUN-PILOT for the Optics Industry is a disruptive technology that will boost the performance/cost ratio of photonic devices by piloting mass fabrication of scratch and wear resistant nanopatterned antireflective optical surfaces. Significant enhancement will be achieved in the efficiency of optical components and systems incorporating these devices, such as laser systems, electronic displays, security cameras and medical devices. The Automotive Industry will benefit from a novel method to produce functional surfaces at lower cost and lighter weight than existing lamination methods. This proposal brings together scientists and engineers to span innovation, business development and the product cycle from suppliers to end users and will ensure a leadership role of for Europe.