Kraken

The objective was to develop a machine capable of producing functional parts up to 20m long, with high accuracy and quality. The parts were made in aluminium, thermoset polymer or a combination of both materials. The KRAKEN concept (ceiling machine) also decreased the floor space needed for the same number of products through the use of a ceiling installation.

The project run from 2016 to 2019 and CECIMO was the dissemination leader.

If you want to know more, visit the project website: www.krakenproject.eu

results

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Multi-material Additive Manufacturing

Kraken developed a new polyurethane paste, a new resin extrusion process, Wire arc Additive manufacturing (WAAM) and an arc spray metallisation process.

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Subtractive manufacturing

The KRAKEN machine has a hybrid additive-subtractive head with an automatic quick tool exchange which allows for a quick switch between additive deposition of material and subtractive operations.

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CAM (Computer Aided Manufacturing) software for hybrid manufacturing

EDGECAM has been modified to enhance its functionality and new CAM algorithms for hybrid manufacturing, including planar horizontal layer additive strategies and new direct 3D freeform approaches, have been integrated.

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Real-time control and monitoring

The high accuracy of the KRAKEN machine is achieved through a closed-loop control of robot motion and end-effector position and orientation (6DoF) in realtime based on absolute laser tracking. It includes also Quality Monitoring systems which allows for early failure detection and correction.

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E-learning platform

Partners developed an e-Learning platform with comprehensive information on hybrid and additive manufacturing processes and the KRAKEN machine.

demonstration cases

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Hybrid lining panels for tunnels

Hybrid lining panels for road tunnels have been manufactured with the KRAKEN machine for ACCIONA Construction. KRAKEN multi-material capability has allowed to embed, into a monolithic part, auxiliary elements such as electrical wiring for the emergency lighting and metal profiles for panels assembly, which can help speed up the installation process.

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Mock-up of a Pininfarina car design

The KRAKEN technology was used to reproduce the exterior style of the Cambiano, a recent Pininfarina showcar. The model has been manufactured in 1:2 scale by the KRAKEN machine and then finished by Pininfarina with other exterior features. Equipped with a structural frame, the hollow demonstration case should be a promising alternative to the manufacture of style models in the near future.

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Aluminium metallic back and front frames for a car

CRF validated the KRAKEN technology by manufacturing the back and front metallic frames of an Alfa Romeo 4C. The KRAKEN technology provided a new solution integrating large material quantities deposition and hybridization between polymeric and metallic parts, currently not achievable with other AM technologies.