Exploring Additive Manufacturing Open Pilot Line (AIMEN's OPL)

In the evolving landscape of European manufacturing, the adoption of digital tools is not without its challenges. The CONVERGING project aims to overcome key barriers, including workforce skill shortages and the general lack of awareness around new digital technologies. A key part of this initiative is the establishment of four Open Pilot Lines (OPLs), hosted at renowned Research and Technology Organizations (RTOs) such as LMS, TECNALIA, FHG-IPK, and AIMEN. These OPLs will provide access to testing, validation, and training for various sectors in the EU manufacturing industry.

Among these, AIMEN’s Open Pilot Line stands out as a hub for additive manufacturing innovation, offering a perfect testbed for integrating cutting-edge technologies into real-world applications, particularly for the PRIMA facilities.

A Hands-On Approach to Additive Manufacturing

The AIMEN OPL focuses on additive manufacturing, not only handling, postprocessing, and transporting heavy metal components but also ensuring traceability of the data generated throughout the entire production process. A central feature of the OPL is the ABB IRB 6660 robot—a powerhouse designed to move large components, housed in a specially constructed chamber that simulates the environment of an additive manufacturing machine.

This realistic setup offers an ideal testing ground for both CONVERGING partners and external companies, providing an opportunity to refine technologies and engage in hands-on training activities. By enabling companies to test their innovations in real-life conditions, AIMEN’s OPL significantly reduces the barriers to entry for new digital technologies in the manufacturing space.

Current Developments and Future Prospects

The AIMEN OPL is more than just a physical space—it is a digital ecosystem that integrates multiple advanced modules developed within the CONVERGING project. These include:

• Dynamic Work Reorganization (DWR): Optimizes workflows and adapts to changing environmental conditions.
• AI-Station Controller (AISC): Enhances system efficiency and decision-making by automating key processes.
• Data in Motion (DIM): Captures real-time data during production, ensuring traceability and enabling further analysis.

These modules are complemented by an array of hardware, including safety devices, depth cameras, and other sensors. The data generated by these technologies is further processed and analyzed through the Data at Rest (DAR) module, facilitating long-term insights and optimizations.

Human-Robot Interaction and Ergonomics

AIMEN’s OPL doesn’t just focus on the technological side of manufacturing—it also emphasizes the human element. The Perception and Autonomy Module (PAM) is responsible for detecting human poses and ensuring safe interaction between operators and robots. Meanwhile, the User Experience and Ergonomics (UXE) module calculates ergonomic poses, prioritizing operator comfort and efficiency. These efforts culminate in a more human-centered approach to manufacturing, where technology enhances, rather than replaces, human expertise.

The entire system is mirrored in a digital twin, developed by the AI Digital Twin (AIDT) module, offering real-time visualization of the manufacturing process. This allows operators to simulate and visualize production environments before launch, enabling better decision-making and minimizing the risks associated with trial-and-error approaches.

Integrating VR and AR for Streamlined Programming

In a move that further bridges the gap between digital technology and human operators, the AIMEN OPL is integrating Virtual Reality (VR) and Augmented Reality (AR) tools. These technologies will simplify the programming and teaching of robot paths, allowing operators to use AR to overlay digital instructions onto physical environments. This intuitive approach streamlines the programming process, making it more accessible for operators without extensive technical backgrounds.

A Vision for the Future

AIMEN’s Open Pilot Line is setting a benchmark for the future of smart manufacturing. By combining human expertise with advanced digital technologies, it creates a more efficient, adaptable, and innovative industrial landscape. With AIMEN’s OPL, the future of manufacturing isn’t just about automation—it’s about collaboration between humans and machines, ensuring a seamless, integrated, and intelligent production process.

As AIMEN continues to develop and refine its Open Pilot Line, the European manufacturing sector is poised to reap the benefits of smarter, more agile operations. The OPL not only serves as a testing and training ground but also as a symbol of what the future holds for the manufacturing industry—one where technology and human ingenuity work hand-in-hand.