Is additive manufacturing ready to produce large-scale metal parts?
MultiscaleDED integrates LMD, WAAM-GMAW and WAAM-SAW, combining automation, intelligent slicing and online monitoring to enable faster, more efficient and competitive manufacturing.
MultiscaleDED – Multi-scale and multi-structure additive manufacturing, focused on large-scale additive manufacturing
Large-scale metal additive manufacturing stands out for its ability to efficiently produce complex and customised components with reduced waste. However, the industrial adoption of Direct Energy Deposition (DED) processes faces significant challenges, with low deposition rates being the main limitation, reducing productivity and competitiveness compared with traditional manufacturing methods. The MultiscaleDED project addresses these limitations by proposing a multifunctional platform that integrates three DED techniques: Laser Melting Deposition (LMD), for small and detailed parts; Wire Arc Additive Manufacturing (WAAM) using a Gas Metal Arc Welding (GMAW) power source, for intermediate dimensions; and WAAM using a Submerged Arc Welding (SAW) power source, for large-volume parts.
The latter offers significant potential due to its high deposition rate, but faces challenges such as slag removal and geometric adaptation, which the project aims to address through solutions that are currently unavailable on the market. The objectives of MultiscaleDED include:
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Developing a multi-DED platform combining the three deposition methods;
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Creating automated systems for slag removal and flux recovery in the SAW process;
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Integrating an active cooling system to increase production rates, improve thermal control and enhance mechanical properties;
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Developing advanced intelligent slicing algorithms to optimise the process;
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Implementing an online monitoring system for quality control and defect detection.
Through these advances, the project offers a competitive and sustainable alternative, reducing costs and waste while optimising resource use. The increased deposition rate and stringent control of component properties position MultiscaleDED at the forefront of industrial additive manufacturing.
Project Profile
Project Title: MultiscaleDED – Multi-scale and multi-structure additive manufacturing, focused on large-scale additive manufacturing
Operation Code: COMPETE2030-FEDER-02304300
Specific Objective: RSO1.1 – Promoting research and innovation
Type of Intervention: Research and innovation activities in SMEs, including networking activities
Region of Intervention: Centro
Lead Beneficiary – Lead Promoter: AGIX, LDA
Beneficiaries – Co-promoters: POÇO; PENIMAR; Placido Roque; Universidade de Coimbra; SEAPOWER; Incentahead
Start Date: 01-07-2025
End Date: 30-06-2028
Total Operation Cost: 2.827.704,64€
Eligible Funded Amount: 2 827 704,64€
Total Approved Funding: 2 033 622,61€
Co-financing Rate: 71%
Objectives, Activities and Expected / Achieved Results:
Large-scale metal additive manufacturing stands out for its efficiency and sustainability, but faces challenges such as low deposition rates. The MultiscaleDED project proposes a hybrid platform integrating LMD, WAAM-GMAW and WAAM-SAW, with the latter optimised for additive manufacturing. The project includes active cooling systems, intelligent slicing and online monitoring, increasing productivity and quality while reducing waste.
Promoters
AGIX
AGIX develops, manufactures, and implements industrial robotic cells, fully automated production lines, peripheral equipment, and customized solutions, laser cutting systems, conventional machine vision systems, and deep learning-based vision systems, as well as industrial monitoring software.
The company is committed to contributing to the optimization and innovation of industrial production processes by developing technology-driven solutions aimed at increasing the efficiency and competitiveness of the industry.
POÇO
Since its foundation, Poço has focused its activities on the metalworking industry, specifically on the development and manufacture of industrial equipment, including overhead cranes, industrial weighing equipment, raw material silos, conveyors, elevators and steel structures, among many other solutions.
Over the years, the quality of its services has earned recognition both in Portugal and in international markets, enabling the development of new projects for the glass and ceramics industries.
PENIMAR
Penimar is a company specialising in shipbuilding and ship repair, metalwork, hydraulics and mechanical engineering. It was established in 1984 by three partners and has had two partners since 2018.
Over the years, the company has expanded its portfolio of projects through the construction and manufacture of steel and/or aluminium fishing and passenger vessels. Its other activities have been carried out throughout mainland Portugal, as well as in Madeira, the Azores and Angola.
Placido Roque
PLÁCIDO ROQUE – INDÚSTRIA DE MOLDES E MÁQUINAS, LDA. was established in 1986 and has been part of the Moldetipo Group since 1996. Its headquarters are located at the heart of the Marinha Grande industrial cluster, where the company operates in the design, engineering, manufacture and testing of moulds, as well as in mould maintenance, modification and refurbishment.
Plácido Roque has extensive and proven experience in the automotive, houseware and electronics sectors, as well as in two-component moulds and Water Injection Technology (WIT) moulds. Its target markets are Europe, the Americas and Asia, with 100% of its production exported.
Universidade de Coimbra
The University of Coimbra is a public higher education institution with centuries of experience in teaching, education and research, and is internationally recognised.
Founded in 1290, it was the first and only Portuguese-speaking university until the beginning of the 20th century. It has established a unique position that brings together tradition, modernity and innovation, which led to its classification as a UNESCO World Heritage Site in 2013.
SEAPOWER
SEAPOWER is a technology and innovation centre dedicated to the sustainable development of the Blue Economy. Through the development of innovative projects, SEAPOWER contributes to the digital transformation and decarbonisation of the Blue Economy, with a particular focus on the implementation of sustainable technologies and strengthening the competitiveness of the blue ecosystem.
SEAPOWER positions itself as a hub for innovation, skills development and knowledge transfer, aiming to promote knowledge and innovation within the Blue Economy at both national and international levels.
Incentahead
IncentAHEAD’s mission is to create value for its clients by promoting the sustainable development of companies through specialised management consultancy services, with a strong focus on incentive schemes under Portugal 2020.
IncentAHEAD has established itself as a leading management consultancy firm specialising in incentive schemes, providing support for internationalisation, innovation, business qualification, research and development, as well as tax incentives.
