COMIC project consolidates its developments in multimaterial manufacturing and digitalization in its third year

The main conclusions drawn from the completion of the third year of the COMIC project at the global consortium level can be summarized as follows:

ACT1 – Embryonic data space for multimaterial manufacturing value chains

• Progress has been made in the development of the digital platform, adding and improving functionalities, making it more robust.
• A functionality has been implemented to import historical data from devices (in .csv format), which can be visualized on the platform through the Graphs and Reports section.
• Open Metadata has been integrated into the platform for data governance.
• A system for managing and controlling access to the platform has been developed, with different permission levels, to ensure the cybersecurity of the information.

ACT2 – New multimaterial component concepts

• The numerical models for performing structural simulations have been updated, thanks to data provided by experimental tests.
• Based on these simulations, the design and materials of new components to be implemented in the 3 use cases have been optimized.
• The optimized components have been validated through specific tests on prototype parts.

Figure 1. Final design example of UC1 part, with integrated patch for initial design validation through mechanical testing.

ACT3 – Highly flexible new processes for multimaterial manufacturing

• Development and fine-tuning of new technologies for the 3 use cases have been carried out, with some already being validated.
• Use Case 1 – Automotive: FML patch manufacturing technology development for suspension arm reinforcement, patch stamping process on suspension arm.
• Use Case 2 – Automotive: Mold development and press assembly for initial tests with final part.
• Use Case 3 – Aeronautics: Mold manufacturing for obtaining omegas, development and implementation of welding head improvements for resistance welding of omega to laminated component (skin), resistance welding process optimization.
• The different processes have been supported by simulation for faster and more efficient development.

Figure 2. Final mold for manufacturing UC2 part, ready to be integrated into the press.

ACT4 – Digital strategies for flexible and zero-defect manufacturing

• A Digital Twin prototype has been developed as a platform, directly connected to the embryonic data space from Activity 1 of the project, as well as the development of new capabilities for simulating industrial data that facilitate scaling and configuring new production scenarios.
• A tool capable of integrating manufacturing technologies in their design and simulation processes has been developed.
• Sensors (pressure, temperature, impedance, etc.) have been implemented in the different molds of the 3 use cases, along with hardware for data acquisition and software for data capture, as well as communication with the data space via OPC-UA.
• NDT technologies have been developed to address the different quality controls and monitoring for each of the three Case Studies, applying both surface and volumetric inspection techniques.
• Various AI layers have been developed and applied to optimize control, monitoring, measurement, quality control, data flow, and more.

Figure 3. Application of UT technologies for non-destructive quality control of parts in UC3.

ACT5 – Validation of flexible and reconfigurable manufacturing of new multimaterial components – TRL5

• Integration of the technologies developed in the previous development activities has begun, with varying degrees of progress depending on the use case.

FAGOR ARRASATE participates in this project alongside DGH ROBOTICA, AUTOMATIZACION Y MANTENIMIENTO INDUSTRIAL, S.A., AUTOTECH ENGINEERING, S.L., SOFITEC AERO, S.L., INESPASA, ENDITY, and MANAGING COMPOSITES, S.L. Additionally, several renowned technological centers are also subcontracted within the consortium, including IDEKO, ITI, KONIKER, TEKNIKER, and AIMEN.

This project has been funded by the CDTI and supported by the Ministry of Science and Innovation.

More information about the project: COMIC Project