IMAGiC

3D printing and hydrogen innovation for GigaCasting optimization.

IMAGiC develops additive manufacturing solutions and new thermal processes to improve the production of large-format components for the automotive sector. The project aims to make the manufacturing of structural parts more efficient, reducing cycle time and environmental impact.

The project focuses on GigaCasting, a technique that allows the manufacturing of vehicle chassis sections in a single large piece of aluminum. This method replaces the traditional assembly of stamped sheet metal parts that had to be joined individually, which reduces vehicle weight, saves raw materials, and simplifies the production chain.

To improve this process, IMAGiC uses metallic 3D printing to create the casting molds. This technology allows for the integration of internal cooling channels with complex shapes that optimize heat extraction. Thanks to this improved thermal control, the manufacturing time for each piece is shortened by up to 40%, which improves productivity and the quality of the final product.

A further key pillar is sustainability and scientific research. The project is developing a furnace demonstrator for thermal treatments that runs on 100% hydrogen. This innovation, on one hand, eliminates CO2 emissions derived from the natural gas typically used to heat the furnaces and provide the necessary mechanical properties to these giant dies. On the other hand, it investigates complex phenomena such as hydrogen embrittlement in 3D-printed steels.

The objective is to design ultra-high-strength steel microstructures that are immune to this phenomenon, guaranteeing the durability of the giant dies.

Eurecat participates in this project through its Metallic and Ceramic Materials unit, which provides its expertise in material characterization and in validating the behaviour of steels against the use of hydrogen and new manufacturing processes.

The consortium is led by ROVALMA, a company specializing in high-performance steels and special alloys, and also features the collaboration of CENIM-CSIC and the ALBA Synchrotron.