Projects

Topics

Two major disruptive trends – electrification and digitalization are changing customer preferences, leading to the probably most substantial transformation in the automotive industry we observed in decades. Finding a balance between customer’s requirements towards “zero-emission vehicle,” “connected car,” choice of materials, clarity of functions, and interface modes under the pressure of production time and cost are not easy. The AttributDo-project aims to help engineers create, define, verify and validate new and existing design features for new product development.

2021 – 2021

Automotive components from renewable resources with good barrier properties and tailored biodegradability, for interior applications

Our hypothesis is that advanced, lightweight, multi-layer-structured composites with good barrier properties and tailored biodegradability can be produced by combining bio-based thermoplastic with special additives and pulp fiber mats. This material is free from fossil raw materials, sustainable, fire and impact-resistant and suitable for interior components in vehicles.

2012 – 2013

Compact and energy efficient transmissions – control and prediction of functional surface behavior

The overall objective of the project was to: • Develop simulation methodology for drive simulation of transmissions with given shape, surface topography and surface structure, - for more robust and better prediction of the efficiency and life of gear contacts in gearboxes. • Through experimental evaluation and characterization, support and verify the developed simulation technology • Through experimental evaluation and characterization, further verifying the potential of using the correct surface texture, e.g. honing, and right-handed gear in heavy-duty transmissions.

2016 – 2018

Dense-Arc joining of hybrid thermoplastic composite-metal structures (DENSARC)

The aim with the project is to test a new method to join thermoplastic composite to metal in a lap joint by using a focused TIG arc, as a heat source, to heat the metal side just enough so that the composite melts and join to the metal. The method gives single sided access, no need for additional filler material and makes invisible joints possible. The objective is to have a joining method that is robust, gives high productivity and high quality as well as cost advantages.

2012 – 2013

Digital innovation for railway production value chains

makeITrail is concerned with developing new methods and technologies to further integrate the value chain of railway manufacturing in Sweden. It aims to strengthen the supplier-producer-consumer relationship and connect local suppliers internationally. The project focuses on several strength areas in Produktion2030, like flexible production, virtual production, integrated product development, and resource efficient production. These areas link to the agenda of sustainable development 2030; in specific, “industry, innovation, and infrastructure” goal, and “responsible production and consumption”. The consortium consists of: Bombardier Transportation, HiTest, DELTA Development Technology AB, Mälardalen University, and the Research Institutions of Sweden.

2019 – 2019

Digital value chain for geometry data management (DigiGeo)

Increased digitalization brings new possibilities for Swedish manufacturing companies. This project focuses on what data are needed to feed assembly variation simulation and how this data can be captured and stored efficiently and effectively. The project contributes to increased geometrical quality. The technical value chain from part inspection, to extraction of relevant data, storage of data, usage of data in variation simulation (as a digital twin) and to visualization of simulation results as decision support will be covered. This has the potential to replace prototypes/test series and saves cost, time and reduces the environmental impact.

2019 – 2019

Effective construction of sandwich structures for energy efficient personal transportation

The transition from conventional to electric power lines creates many challenges, but also opens up new possibilities for component packing and design of load bearing structures as well as new manufacturing methods. The project aims to exploit opportunities with sandwich construction to reduce weight and hence the energy consumption for propulsion; reduce heat losses and hence energy consumption for climate change and to reduce manufacturing costs using new manufacturing concepts, rational assembly and new construction technology.

2017 – 2020

Effective construction of sandwich structures for energy efficient personal transportation

Emerging digital technologies and their applicability as picking support in materials handling

In material handling processes, such as kitting and sequencing, which are used in the automotive industry to supply the assembly with a wide and growing range of component variants, the picking information system is central design aspect. Given the developments in digitization, the purpose of this concept study is to evaluate the potential of digital technology to support materials handling work in production systems.

2017 – 2017

Enabling REuse, REmanufacturing and REcycling Within INDustrial systems (REWIND)

The REWIND project combines the principles of lean production and eco-efficiency in three industry pilots at Stena Recycling, Volvo AB and IKEA GreenTech. The objective is to retain the value embedded in materials with circular strategies (reuse, remanufacture, recycle, repurpose, etc.). Lessons learnt from the pilots will be used to develop educational tools for engineers and industry leaders to accelerate the uptake of best practices for circularity and sustainable production.

2019 – 2022

Enabling super quality electric steel through advanced use of data analytics in real time

The revolution of electrical vehicles has started and several of the major carmakers have declared that the goal will be met within the next 2-3 years. This cause increased needs for qualitative steels for electrification of vehicle pow er. Suppliers of electrical metals does not meet the needs for high quality input materials. The SuperSteel project will investigate how a project that combines know ledge capture and management, data management and advanced analytics from all actors in the supply chain can be implemented to realise the required product quality in a flexible production.

2017 – 2018

Flexible Models for Predictive Maintenance

Maintenance in existing plants is becoming increasingly important, where predictive maintenance has become an emerging technology. The use of decision support tools contributes to environmentally and economically sustainable production. Within this project, different types of digital twins have been designed and evaluated. Specifically, new predictive model types have been tested in two different industrial case studies; a heat exchanger at SSAB and a profiled header at Svenska Fönster AB.

2017 – 2018

Geometry optimized adhesive joining for sustainable production

"Geometry Optimised adhesive joining for sustainable production” in Swedish (Geometri Optimerad LimFogning för hållbar produktion, "GOLF") is a project within the Swedish research program FFI for Sustainable production. It has as its mission to develop technology and methods to get the right amount of adhesive on the right place. The drivers behind this are the overall strive to decrease weight in vehicles and moving machines to minimize the amount of CO2 in the atmosphere.

2013 – 2015

HJT-Hybrid Joining Test bed for smart production

Hybrid joints, combination of gluing and mechanical joining are highly demanded where several materials are to be used and assembled. HJT therefore focuses on the smart factory's ability to create flexible production with simulation and programming in a digital twin that combines the latest technology for bonding, assembly and mechanical joining, rheology based simulation and automated collision-free planning. The projects goal is to focus on the whole hybrid joining process and to establish a testbed for hybrid joining as a resource for Swedish Industry.

2017 – 2020

Humle – Human Perspective, Machine-Learning ERP-systems

This project aims to contribute to the development of future ERP-systems. The project will explore how to offer work, redefine work roles and challenge companies to make use of advanced systems support and the technology within and around these. Overall, the project aims to contribute to the development of both the next generation of ERP-systems and a complementary change in the way firms see upon work organization, so that technology can support and meet the needs of the humans within organisations rather than enforcing structures upon them.

2019 – 2019

Impact of particles in production of particle sensitive systems pre-study for new requirements for new components

With the right knowledge about efficient handling and reduction of particle occurrence during production, you can use resources correctly, get rid of waste and get products that last longer. By using the right measures in the right place, you can reduce water, chemical and energy consumption, thereby creating sustainable production. By being able to evaluate the effect of particles, you can set the right requirements, so that today's and eventually tomorrow's products work longer without failure.

2021 – 2022

Infrastructure for Digitalization enabling industrialization of Additive manufacturinG – IDAG

IDAG aim to identify gaps and propose actions for the digital infrastructure necessary to industrialize additive manufacturing technologies. Actors from a new type of value chain of manufacturing companies – from powder to product – collaborate with digital solution providers and researchers to understand the needs and articulate the necessary actions through analysis of industrial cases. The target is to deliver a description in the form of a roadmap for how these actions can be developed and provided in order to ensure flexible and scalable digital platforms for additive manufacturing value chains.

2019 – 2019

Lightweight electric vehicle assembly by friction stir welding (EVASTIR)

The EVASTIR project will support the Swedish automotive industry with the transition from internal combustion engine to battery electric vehicles, while introducing new sustainable manufacturing processes. This project will develop a welding process, FSW, to support design and fabrication a cost-effective, scalable, lightweight and crash-resistant battery tray for electric vehicles. The specific technical objectives of this project are to develop FSW procedures for dissimilar material joints of cast and extruded aluminium alloys and for high speed welding to 5m/min.

2019 – 2021

Lightweight electric vehicle assembly by friction stir welding (EVASTIR)

Non-poisonous substitute for hard chrome in volume applications

This project explores the possibility of replacing hard chrome coatings on steel in volume applications with the Swedish innovation, TiSurf, which is a hardened nitride surface on titanium with excellent chemical and mechanical resistance. The long-term objectives are a more sustainable and cost-effective production of environmentally friendly hybrid materials to replace cancerogenic chrome based hard coatings and to create new application opportunities and markets. Therefore, the objective of the project is to develop and evaluate possible processes for hardened nitride surface on titanium with respect to relevant material and mechanical properties, to investigate and verify its potential as a sustainable replacement material for hard chrome and in various applications, such as piston rods, axles and tubes.

2017 – 2018

PADOK – Study Visit to India 2016

With globalization and other megatrends as demographic changes and climate change, more knowledge is needed regarding production in an international perspective. PADOK Study Visit in India 2016 have given an increased knowledge regarding how production is conducted in India, some of the challenges producing companies in that region is facing and how Swedish companies interested in investing in production in India could act to establish themselves in the region.

2016 – 2016

Polyfree 2.0

Cyclicor, which has its origins at Lund University, has in a previous project within Mistra Innovation successfully developed a method for producing the plastics polycarbonate (PC) and polyurethane (PU) without toxic additives. One goal of the Polyfree 2.0 project is to increase the production of the new plastics from lab scale to quantities that enable the participating industrial companies in turn to take steps towards finished products. Other goals are for the plastics to be recyclable as well as have the required properties.

2021 – 2023

Polyfree 2.0

SCARCE II – Sensible Value Chain through Digitalised Planning, Materialhandling and Circular Economy

SCARCE II will develop a demonstrator to show how SMEs and associated value flows can increase efficiency, competitiveness, sustainability and internal collaboration through digitalisation. The goal is to show the value of a new digital solution. SCARCE focuses on two subcontractors in the value chain linked to Scania and Volvo. The demonstrator is a cloud-based solution that connects three test beds in the industry; Stena Industry Innovation Lab, Chalmers, RISE IVF lab, Mölndal and KTH's test bed in Södertälje with the help of Siemens, AFRY, Qbim, Virtual Manufacturing and EQPack.

2020 – 2022

SCARCE II – Sensible Value Chain through Digitalised Planning, Materialhandling and Circular Economy

Secure Shortcut (See Cut)

SeeCut focuses on cost-efficient production systems for secure collection, analysis, visualization, storage and sharing of production data. The project addresses the integration of new signals and sensors. For advanced products, like jet engine components, collecting data during manufacturing and usage is essential for quality assurance and remanufacturing. The project goals are to identify key technical requirements related to production data for use in digitalized value chains, define means to ease the run-time integration of new signals and data streams from manufacturing machinery and sensors, and define how to securely and cost-efficiently share data through the value chains in circular production.

2019 – 2019

Sensible Value Chain: Material Flows, Roles and Circular Economy – SCARCE

SCARCE will investigate the needs, possibilities and obstacles in value chains up- and down-stream from a focal SME company. SCARCE will explore what data to measure and visualize, and how this data can enable more automated execution, as well as, more dynamic and proactive planning of production capacity and material flows across the companies in the value chain. In addition, we will study organizational capabilities, especially the future human role, for implementing and managing in a digital and data-driven value chain.

2019 – 2019

Sintered parts with high static loading capacity

The project has confirmed the hypothesis that tailoring of the tempering is a functioning means of making PM steel sustainable towards high static loading in potential automotive applications. The project has also developed further understanding about mechanisms that could be responsible for static loading sensitivity with respect to creep/relaxation at slightly elevated temperature. The results relate to sustainable manufacturing processes, the basis being that powder compaction and sintering is an energy efficient way with high raw materials utilization.

2012 – 2013

Streamlined Modeling and Decision Support for Fact-based Production Development (StreaMod)

The integration of data management systems, simulation software and optimization algorithms have been shown to increase throughput in existing production but also allow expanded use of virtual tools in the preparation phases. This in turn leads to shorter development times for new production systems and products. The project has also contributed to greater understanding and concrete improvements in the processes of collecting and assure the quality of production data. This in turn increases the quality in both simulations and direct data-driven analyzes.

2013 – 2017

Sustainable Manufacture of Future Engine Components

The project has addressed challenges in casting and realisation of new cast irons with improved properties and machinability, decision making regarding manufacturing strategies and machinability of materials. Silicon-alloyed compacted graphite iron (CGI) has been demonstrated av new alternative for future engine components. New simulation technique for assessing manufacturing strategies has been introduced. Generic know ledge has been developed w hen it concerns w ork material machinability w ith specific reference to combined materials in advanced components.

2012 – 2015

Sustainable Metal Powder Utilization in Powder Bed Fusion Additive Manufacturing

This project intends to design and develop a new test methodology for evaluation of power flowability in powder bed fusion (PBF) systems. The test apparatus will simulate powder flow in PBF machines and can be used for optimizing the powder layering behavior for potential utilization of alternative powder qualities. Additionally, this equipment creates opportunities for both powder producers and AM part manufacturers to minimize powder waste and maximize material utilization.

2017 – 2018

Sustainable Metal Powder Utilization in Powder Bed Fusion Additive Manufacturing

Tailored Tool Surfaces for Robust and Sustainable Hot Stamping

Tooling constitutes a significant part in the economical investment of the hot stamping process. Significant benefits in production economy and environmental benefits can be attained by improving the tribological performance in hot forming operations of automotive components. The main idea of this project is to create tailored tool surfaces on dies made from cheaper and easier to manufacture tool steel for the hot stamping of ultra-high strength steels.

2015 – 2018

Tailored Tool Surfaces for Robust and Sustainable Hot Stamping

Total offerings in manufacturing industries in Sweden – a lift

Potential to increase sales is large in companies that manage to switch from supplying goods with strong price competition to develop and deliver total offerings with a higher perceived value for the customer. The project aims to contribute to more manufacturing SMEs in Sweden realizing this potential. The goal is to develop and pilot test a scalable model for coaching SME´s shift towards creating and delivering innovative and sustainable total offerings and thus enhanced competitiveness. The project will also develop a plan for further scaling up from 2017 onwards.

2013 – 2016

Variation Prediction and Source Identification for Zero-defect Machining Line

In multi-stage machining, errors or variations in machined part features propagate downstream from process to process through the entire machining line. The objective of the project is to enable achieving a zero defect production by predicting and controlling variation and their propagation in multi-stage machining. This demands capturing the relations between variations and their sources in a multi stage machining. The project activities will be based on three industrial cases at Scania, LEAX AB, and GKN. The cases are meant to ground the already proven state of the art concepts in variation modelling, data analytics, measurement, precision pallet system, and simulation in real industrial applications. The application area of the project result covers manufacturability analysis, tolerance analysis, process planning as well as quality assurance strategies. The results and the demonstrations will be of interest to SME and large companies having multi stage machining.

2016 – 2018

Virtual PaintShop – Simulation of Oven Curing

The paintshop is often a bottleneck in production and the processes are fine-tuned based on testing on numerous prototypes. To meet the future demands there is a great need to improve the product preparation process. The aim is to develop methods, techniques and software, and supporting measurement methodology, for simulation of paint curing in IR and convective ovens. The goal is to assist the industry to further develop and optimize their surface treatment to be more energy and cost efficient; to have a shorter lead time in product development; and to give a higher product quality.

2016 – 2019

Virtual PaintShop – Simulation of Oven Curing