• The specialised publication in the additive manufacturing and 3D printing sector highlights DISCMAM’s work on digital qualification for LPBF, bringing the project’s latest technical developments to a wider audience

The technical developments achieved within the DISCMAM project continue to reach the wider Additive Manufacturing community. Further extending the impact of the project’s results, Additive Manufacturing has published the article “Digitally Qualifying LPBF Parts for Defense Applications”, showcasing some of the work carried out by the consortium to advance quality assurance for on-site metal Additive Manufacturing.

The article brings together contributions from DISCMAM technical partners Danish Technological Institute (DTI), LORTEK, Fieldmade and Euler. It is authored by Dr Daniel F. S. Ferreira, Dr Juan Carlos Pereira, Dr Marta Muñiz, Dr Tobias Rønneberg and Dr Hildur Einarsdóttir, reflecting the collaborative research behind the project’s digital qualification developments.

Digital qualification for more reliable on-site manufacturing

How can the quality of an LPBF-produced part be assessed when conventional laboratory testing is not readily available? This is the central challenge explored in the article. Within DISCMAM, partners are investigating how the digital footprint generated during the manufacturing process can provide evidence of part quality, reducing reliance on resource-intensive physical testing when manufacturing closer to the point of need.

The work combines in-situ process monitoring, AI-based defect detection and a fast-response digital twin to transform manufacturing data into useful quality information. Based on this digital evidence, the approach supports the classification of produced parts according to different functional acceptance levels, helping to inform decisions on their potential use.

The methodology has been tested on two aluminium use cases, a Unimog compressor cover and a fuel filter housing, produced using Laser Powder Bed Fusion (LPBF). The research also examines how process events detected during manufacturing relate to relevant indicators, including porosity, geometric deviation and surface properties.

These developments contribute to DISCMAM’s broader work towards more reliable and data-driven metal Additive Manufacturing, supporting quality assessment in portable production environments.

The approach has already been showcased by DISCMAM partners during AM Village 2026 in Albacete, Spain, where participants saw how digital quality assurance could help assess the quality of manufactured components beyond what can be determined through visual inspection alone.

The publication in Additive Manufacturing provides a closer look at the methodology, testing and results behind this work, as well as its potential contribution to the future qualification of LPBF-produced parts.

About Additive Manufacturing

Additive Manufacturing is a specialised media brand focused on the advancement of industrial 3D printing. Its coverage explores the technologies, applications and trends driving additive manufacturing forward, from tooling and functional prototypes to end-use production parts.

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• A new DISCMAM use case shows how metal additive manufacturing can transform the production of obsolete spare parts, reducing lead times from weeks to hours through digital manufacturing and quality assessment.

Within the DISCMAM European Defence Fund project, coordinated by LORTEK, the Danish Technologial Institute (DTI) worked with the Belgian Ministry of Defence on a replacement solution for a compressor cover for a Mercedes-Benz Unimog U1300L / 435 series. This vehicle platform dates back to the late 1970s/1980s, meaning many units still in operation are now around 40 years old or more. The compressor cover is an obsolete cast aluminium spare part that can fail due to leakage at the joint. The challenge was not only to reproduce the part, but to make it suitable for fast, on-site oriented production where access to machining, post-processing equipment and testing facilities may be limited.

At the Industrial 3D Print, in the Danish Technological Institute, the part was:

• 3D scanned and digitally reconstructed.
• Adapted for PBF-LB metal 3D printing.
• Produced in AlSi10Mg.
• Optimized to reduce support structures by approx. 30%.
• Printed without supports or machining in critical functional areas.
• Supported by digital quality ranking using in-situ process data.

An important part of the work was the development of a digital quality assessment approach. Using PCA-based statistical analysis of in-situ Euler data, it is now possible to detect part outliers and rank printed components according to their expected usability. A PCA-based quality map enables rapid digital ranking of printed parts, supporting replacement decisions when physical testing is limited. Based on the level of urgency and the quality indicators, parts can be classified for permanent replacement, temporary replacement, emergency use, or finally rejected as scrap. This provides a valuable decision-support tool in situations where physical testing facilities are limited or unavailable.

The result is a production route where the part can be printed in approximatry 8 hours when aiming for a permanent replacement. For temporary or emergency replacement scenarios, the route can be further accelerated, depending on the required quality level and urgency. This is a significant improvement compared to a traditional supplier lead time of approximately 2 weeks. This case shows how additive manufacturing can help reduce downtime, restore access to obsolete spare parts and enable faster maintenance operations closer to where the need occurs.

• Recent achievements in process optimisation, digital quality assurance and secure data-sharing capabilities are paving the way for the upcoming demonstration activities.

The road towards the final validation of the DISCMAM solutions brought project partners together in Reykjavík, Iceland, on 11 June 2026 for a strategic meeting focused on integration, final demonstrations, KPI measures and project closure.

Hosted by project partner Euler at the iconic Harpa Concert Hall, the consortium meeting provided an opportunity to review the progress achieved over the last six months and align the activities and actions required for the final phase of the project.

The discussions focused on the final integration phase of the hardware and digital developments delivered throughout the project for both Directed Energy Deposition – Laser Beam (DED-LB) and Powder Bed Fusion – Laser Beam (PBF-LB) technologies. These activities are essential to achieve the final project milestone: the validation of all systems and digital solutions, the measurement of key performance indicators (KPIs) and the completion of the benchmark analysis demonstrating the value of the DISCMAM approach for secure on-site metal Additive Manufacturing.

Key developments pave the way for final validation

Over the past months, significant progress has been achieved across the project’s technical work packages, completing key developments and implementations that now form the foundation for the upcoming demonstration and assessment activities.

One of the major achievements during 2026 was the successful completion of the milestone “Optimised manufacturing strategies to ensure quality in portable Additive Manufacturing systems”, led by ADAXIS. This milestone concluded the work package dedicated to developing digital solutions for on-site process optimisation, quality assurance and manufacturing efficiency.

The completed developments include advanced 3D scanning and geometry recognition methodologies, DED-LB path planning and deposition optimisation strategies, quality assurance frameworks for portable metal AM systems and fast-response predictive models capable of supporting real-time process assessment and quality evaluation.

Together, these developments provide the technological foundation required for the integration and assessment of the DISCMAM innovative solutions in representative operational scenarios.

DED-LB integration moves into the concluding stage

Significant progress has been achieved in the integration of the digital and hardware developments for the DED-LB solution.

Current activities include testing a unified software environment that combines the different modules in the CAM Platform: 3D scanning, path planning, process monitoring and post-processing functionalities into a single workflow. Demonstrations covering the complete process chain, from component digitalisation to manufacturing and repair, have already been carried out.

In parallel, the integration of the new modules in AdaOne platform created by ADAXIS and associated to the particular hardware and systems into LORTEK’s multi-robot DED-LB wire cell is being finalised, creating a unified environment and pipeline where the different digital tools developed during the project can operate together with minimum intervention of the cell operator.

Further advancements include the definition of repair procedures for the second DISCMAM use case, upgrades to process monitoring systems and camera infrastructure, improvements to the remote assistance WebApp and updates to the digital modules supporting process path planning, monitoring and workflow management.

The integrated DED-LB workflow is now approaching the stage where its performance can be assessed through representative repair demonstrations.

Digital tools deployed in the portable PBF-LB solution

During the meeting, it was also reviewed the latest achievements related to the integration of the PBF-LB solution. Several key digital developments have already been integrated into the manufacturing workflow, including the Cybersecure Digital Pathway testing and validation, enabling secure data exchange and remote support capabilities, the Fast-Response Digital Twins, designed to support process optimisation, and the Digital Data-Driven Quality Module, which enables part quality assessment using manufacturing process data.

An important milestone has also been achieved through the integration of Fieldmade’s portable NOMAD®03 system within the DISCMAM framework. In parallel, the digital developments validated at the Danish Technological Institute (DTI) are currently being transferred to the portable platform in Fieldmade, supporting the deployment of a complete and fully operational PBF-LB solution.

With the core technologies now integrated, the focus shifts towards demonstrating their combined performance and assessing the overall DISCMAM approach.

Focus on the last DISCMAM milestone

The next stage of the project will centre on repair and manufacturing demonstrations based on the selected use cases for both metal AM technologies, assessing the performance of the integrated solutions, the complete digital workflow and the secure data-sharing capabilities developed throughout DISCMAM.

The results obtained will contribute to the measurement of project KPIs and the completion of the benchmark analysis required for the final project milestone.

Alongside the technical work, the consortium is also advancing exploitation activities aimed at maximising the long-term impact of the project. This includes the development of a business plan exploring future commercial opportunities and a technology roadmap outlining how DISCMAM results could be adopted within the European defence ecosystem.

As the project moves towards completion, partners are now concentrating on the remaining assessment, exploitation and dissemination tasks ahead of the final demonstrations planned before DISCMAM concludes in November 2026.

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• Insights from Fieldmade on the key PBF-LB capabilities supporting the integration and validation of the DISCMAM solutions.

As DISCMAM enters the final six months of the project, the consortium is focusing on its final validation phase. On the Powder Bed Fusion Laser beam (PBF-LB) side, Fieldmade is leading the integration and validation of the DISCMAM solutions within its NOMAD®03 portable metal Additive Manufacturing system.

We spoke with Nils Knofius, Head of Digitalisation, and Tobias Rønneberg, Head of Quality at Fieldmade, to discuss the key capabilities being demonstrated, the role of secure digitalisation and what successful implementation and validation could mean for the future of on-site metal Additive Manufacturing. The objective is to demonstrate how advanced digitalisation, secure communication, in-field testing and data-driven quality assurance can support reliable on-site manufacturing operations for spare parts production.

The objective is to demonstrate how advanced digitalisation, secure communication, in-field testing and data-driven quality assurance can support reliable on-site manufacturing operations for spare parts production.

Key capabilities under validation

One of the key capabilities currently being validated is digitisation of parts using semi-automatic hardware and easy software. As explained by Nils Knofius, “If we can get this going, we will achieve higher consistency of the input data used to create design 3D files. This makes the approach more efficient (less back and forth) and increases the quality 3D models and as a consequence of the produced parts”.

Another important aspect of the validation is sending Technical Data Package (TDP) and quality data for parts securely via the cybersecure digital thread to the NOMAD®03, enabling the company to rely on reach-back functionalities. This means that not all activities surrounding on-site manufacturing need to be performed in the field, as certain engineering tasks can instead be carried out at a centralised location.

For Fieldmade, this also represents an important step towards interoperability with wider defence digital ecosystems. “This brings benefits in terms of leveraging expertise and potentially relying on a more advanced digital infrastructure. Furthermore, it lightens the load of the operators on-site”, noted Tobias Rønneberg.

Advancing digital qualification for on-site production

One of the most important innovations being validated within DISCMAM is the concept of digital qualification for on-site manufacturing. According to Fieldmade, this remains one of the main challenges for wider adoption. “If we can improve on that this is a major step ahead since it will significantly increase the part portfolio that can be produced on-site with confidence”, added Tobias Rønneberg.

Traditional quality assurance methods often rely on sending parts to specialised labs or testing centres, which defeats the purpose of on-site manufacturing. Alternatively, visual inspections performed by equipment operators can only identify surface-level defects and remain highly dependent on individual judgement.

To improve the current situation, DISCMAM is exploring the use of robust and easily transportable equipment for in-field testing and in-process sensors capable of capturing sufficient quality-related data directly during production.

The objective is to provide greater confidence in manufactured components while reducing dependence on traditional testing procedures.

As Nils Knofius explains:

“For Fieldmade the key is of course that we are ready to easily integrate with the digital military platforms and infrastructure. Normally this is a cumbersome process for SMEs. By now having the possibility to test our system with a compliant digital communication pathway makes us future proof and interoperable with the wider defence ecosystem”.

What would make this validation a real step forward?

The final validation phase will focus on demonstrating how these capabilities perform outside controlled factory environments and in the entire workflow.

A key objective for the DISCMAM partner will be benchmarking digital qualification methods against traditional laboratory testing approaches. “Based on first results we are quite confident that we will be able to show that we are close to laboratory testing insights (of course a fully equipped lab will always have some sort of edge)”, highlighted Tobias Rønneberg.

This would represent a significant step forward, as it would make the production of critical components in the field becomes a realistic option. It would also provide a viable pathway for large Original Equipment Manufacturers (OEMs) to make part of their portfolios available for deployed production of their spare parts.

Ultimately, this would contribute to increased resilience, improved system uptime and greater operational readiness for allied forces, addressing one of the most pressing challenges in modern defence logistics.

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• Both EDF-funded projects combine complementary strengths to deliver more resilient and decentralised defence solutions, reducing reliance on traditional supply chains.
• Shared partners Danish Technological Institute (DTI) and CenSec strengthen collaboration by enabling knowledge exchange and closer alignment across activities in both projects.

Europe is increasingly focusing on strengthening its capacity to operate in complex and demanding environments, where rapid response, secure supply chains and technological independence are essential. In this context, the European Defence Fund (EDF) plays a key role in supporting and funding collaborative projects that drive innovation and reinforce Europe’s industrial and technological base.

Against this backdrop, the DISCMAM (EDF 2022) and INNOSWAMP (EDF 2024) projects offer a clear example of how complementary initiatives can create added value when their approaches are aligned. By bringing together expertise in additive manufacturing, advanced materials and digitalisation, both projects highlight the importance of collaboration in maximising the impact of European-funded research.

From centralised systems to on-site capabilities

Although their application areas differ, both research projects are aligned in a common objective: bringing critical capabilities closer to the point of need. This shift towards more decentralised and flexible solutions reduces dependence on traditional supply chains while improving responsiveness in challenging scenarios.

DISCMAM focuses on enabling on-site production and repair of metal components through additive manufacturing routes and digitalisation solutions, supported by a secure digital thread that allows remote assistance and data exchange. INNOSWAMP, in parallel, is developing a new generation of water pre-filtration systems based on advanced materials, designed to improve efficiency, reduce energy consumption and adapt to varying operational conditions.

Both initiatives reflect the EDF’s ambition to foster advanced, collaborative technologies that strengthen Europe’s strategic autonomy. Their shared use of additive manufacturing, innovative materials and digital solutions contributes to more efficient, adaptable and resilient systems capable of operating in remote or resource-constrained environments.

Unlocking synergies through innovation

The synergies between DISCMAM and INNOSWAMP become particularly evident at the intersection of digitalisation, materials innovation and manufacturing processes. The secure digital infrastructure developed in DISCMAM enables traceability, data-driven optimisation and remote support, opening possibilities that can extend beyond its initial scope.

At the same time, INNOSWAMP’s work on functionalised materials introduces new opportunities for integration into future deployable manufacturing solutions. Together, these developments point towards more versatile systems capable of addressing multiple operational needs in a coordinated way, while minimizing energy consumption and waste.

Towards a more resilient and sustainable Europe

Beyond their technological contributions, both projects support broader European priorities. By enabling localised production and reducing reliance on external supply chains, they reinforce technological independence and resilience. Their approaches also contribute to sustainability, promoting more efficient use of resources, whether through repair and on-demand manufacturing or improved water treatment processes.

This collaboration is further strengthened by the participation of common partners such as the Danish Technological Institute (DTI) and CenSec – Center for Defence, Space & Security, both based in Denmark. Their involvement facilitates knowledge exchange and alignment between the two initiatives, enhancing their overall impact within the European innovation ecosystem.

The connection between DISCMAM and INNOSWAMP underlines the value of building links between projects funded under the same European framework. By combining expertise across different domains, these initiatives contribute to a more integrated, efficient and forward-looking technological base in Europe.

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Follow the joint journey of DISCMAM and INNOSWAMP towards smarter and more resilient technologies!

• The work delivered, led by ADAXIS, brings together digital capture, process optimisation and data-driven quality assurance, paving the way for full system integration, digital twin and validation within DISCMAM.

Quality assurance in portable additive manufacturing remains a key challenge for on-site production environments. Addressing this challenge, the DISCMAM project has successfully completed the milestone “Optimised manufacturing strategies to ensure quality in portable Additive Manufacturing systems”, marking an important step towards reliable, high-quality digital manufacturing solutions.

This achievement concludes the project work line dedicated to the development of digital tools for on-site process optimisation. Led by ADAXIS, the work has been carried out by a multidisciplinary team with strong roots in European research and extensive experience in manufacturing innovation within the defence sector, contributing decisively to DISCMAM’s steady and consistent progress.

Core technical developments enabling on-site manufacturing

The achievement of this milestone has been made possible through a series of coordinated technical actions, developed with the active involvement of all consortium partners at different stages of the process.

The work began with the definition of methodologies for 3D scanning, view planning and geometry recognition algorithms. Dedicated workflows were established to support 3D scanning prior to manufacturing or repair operations, laying the foundation for subsequent activities within DISCMAM. In this phase, three different 3D scanning solutions were identified and tested across two predefined operational scenarios.

Building on this foundation, a comprehensive methodology was demonstrated for integrating 3D scanning and DED-LB deposition strategies into a CAM software platform, using AdaOne as the central and unified environment. This approach enabled the full virtualisation of the robotic cell for both DED additive manufacturing and 3D scanning operations, ensuring accurate kinematic representation and alignment with the physical setup. 3D scanning played a key role in virtualising damaged components, recognising missing geometry—such as a damaged lug—and supporting repair using the DED-LB wire process.

In parallel, the project addressed the optimisation of laser scanning strategies to ensure quality in deployable PBF-LB systems. This work led to significant advancements for on-site Powder Bed Fusion – Laser Beam manufacturing, including reduced post-processing requirements, adaptable quality levels, increased production speed and enhanced process robustness. Together, these results demonstrate a flexible and efficient approach to the production of temporary spare parts tailored to defence-related operational needs.

Quality assurance and predictive models for on-site operations

Further work focused on the definition of Quality Assurance (QA) and Quality Control (QC) methodologies for portable PBF-LB machines, as well as for LORTEK’s repair solution based on Directed Energy Deposition – Laser Beam (DED-LB), addressing maintenance scenarios relevant to defence applications.

To conclude the activities associated with this work package, DISCMAM developed a rapid-response, system-level predictive model targeting key quality metrics for both PBF-LB and DED-LB technologies. The resulting digital twin directly links in-process monitoring to critical quality indicators such as porosity, dimensional accuracy and surface texture, providing traceable, data-driven evidence of quality for on-site manufacturing and repair operations.

As DISCMAM enters a pivotal phase of the project, almost all committed milestones have now been achieved. This steady progress paves the way for the final stage, focused on the full integration of the developed solutions and on the validation of the complete DISCMAM platform.

• An interview with Dr. Marta Muñiz, researcher and technical project management support for DISCMAM Project.

As the DISCMAM project enters its final year, it continues to advance towards a new approach to improve maintenance and logistics in defence environments. The initiative focuses on developing an innovative business model for remote assisted on-site operations for spare parts manufacturing and repairs, aiming to minimise downtime and enhance the availability of equipment, vehicles, and other essential assets.

During its implementation, DISCMAM has already delivered several key results while addressing relevant technical and operational challenges. These achievements have been made possible through effective coordination and close technical cooperation across the consortium. Led by LORTEK, the partnership brings together Fieldmade, Accenture, Optimus3D, ADAXIS, Euler, Danish Technological Institute (DTI), Eindhoven University of Technology (TU/e), CenSec, and Zabala Innovation, combining industrial know-how and research capabilities to ensure practical and scalable solutions.

To take a closer look at the results achieved to date and the priorities ahead for 2026, we spoke with Dr. Marta Muñiz, researcher and technical project management support for DISCMAM at LORTEK, where she is part of the metal Additive Manufacturing technologies Research Group.

DISCMAM has reached several milestones during 2025. Could you walk us through the most significant achievements and how the process has evolved?

DISCMAM team has made great efforts and progress throughout the 2025 year. Some of the most significant achievements are: (i) The investigation of  dissimilar types of payment schemes and models that countries should implement to secure access to Intellectual Property Rights (IPR) when metal AM technologies are used, (ii) The integration of developments into a Cybersecure Digital Pathway, (iii) The definition of a manufacturing and repairs workflows, (iv) The development of 3D scanning digitalisation technologies applicable to both on-site manufacturing and repair scenarios between others, and (v) The development of a fast response predictive model for monitoring key process parameters for both metal AM technologies addressed in DISCMAM project (PBF-LB and DED-LB).

How would you evaluate the project’s progress so far compared to the initial expectations or roadmap?

The DISCMAM project is progressing smoothly and reaching the milestones defined. Everything is on track with the planned schedule, and we are not expecting any significant delays at this stage.

What have been the main challenges that have been encountered during 2025?

Some of the main challenges that we have encountered during 2025 are related to: (i) The semi-automatic 3D scanning process workflow for broken or damaged parts. Getting reliable, precise and consistent scans for on-site scenarios, all in a semi-automatic manner, turned out to be more complicated than expected. This required a closer coordination between the technical teams within DISCMAM, (ii) The creation of a digital twin model for both metal AM technologies, has also being a complex task, this can be attributed to the fact that there was a high complexity in replicating the metal AM manufacturing process and complexities in a virtual environment.

How have the project partners collaborated to overcome these challenges?

These challenges were successfully addressed thanks to the strong and effective collaboration between the different partners involved in the DISCMAM team working on both metal AM processes and solutions. Thanks to the combination of an open communication together with the complementary expertise and background of the partners, we could work towards achieving practical solutions.

What are the key next steps the consortium will focus on in 2026 marking the end of the project?

The next steps are going to be focused on integrating all the developments carried out into two final technical solutions, one for repairs and one for manufacturing of spare parts using deployable metal AM equipment.

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• The last Consortium Meeting provided an opportunity to assess progress and spotlight major milestones, including advances in on-site metal additive manufacturing that enhance PBF-LB quality and DED-LB repair precision through virtualisation and refined path planning.
• With the project set to conclude in November 2026, DISCMAM enters a pivotal stage where all technological developments will be integrated into a unified, tested and validated solution.

The city of Aarhus in Denmark provided an inspiring autumn setting for the latest DISCMAM Consortium Meeting, which brought together project partners to review progress made over the past six months. The event was hosted by the Danish Technological Institute (DTI), offering participants the opportunity to visit its advanced facilities dedicated to 3D printing technologies.

The meeting focused on tracking ongoing actions and defining the next strategic steps as the project approaches its final year, leading up to completion in November 2026. This upcoming phase will be decisive for the full integration and validation of the developed DISCMAM solutions, marking a key milestone in the project’s roadmap toward demonstrating secure, on-site repair and manufacturing capabilities within defence environments.

Technical progress highlights

The DISCMAM project continues to progress smoothly, with almost six work packages completed and all efforts now focused on successfully achieving the objectives defined for the second reporting period, which began in June 2025.

Over the past six months, the consortium has achieved four key technical accomplishments that mark significant progress in the development of the DISCMAM solution:

• Cybersecure Digital Pathway Pilot – Led by Accenture, this achievement focused on the development of a cybersecure digital framework for file and process data sharing. The solution ensures compliance with EU military platform requirements and enable remote assistance and secure files transfer securing last meter connection with AM machines.
• Monitoring Systems and Manufacturing Workflow Definition – Led by project coordinator LORTEK, this achievement advanced the development of process monitoring systems and established a defined manufacturing workflow. The result delivers an updated strategy for on-site operations, aimed at reducing system downtime while ensuring part quality and functionality for both repaired and newly manufactured components.
• PBF-LB improved scanning strategies for optimum manufacturing quality – Led by DTI. This advancement will minimize post-processing requirements, accelerate production, and improve the robustness of the PBF-LB metal additive manufacturing process and part quality. In conjunction with process monitoring systems and process data analysis paves the way for future digital part qualification without the need for additional on-site testing.
• Virtualization of the DED-LB wire LORTEK cell, including path planning and deposition strategies for repairing a selected use case – Led by ADAXIS. The completion of this task, allows to enhance the efficiency, precision and reliability of the metal AM repair process, helping to identify potential issues and optimize path planning strategies.

Building on these achievements, the project coordination team noted:

“The DISCMAM project is moving forward smoothly, and the current progress aligns with the established timeline goals. The coming months will be critical for the project progress, as all the developments will be consolidated into a final integrated solution”.

Strong collaboration and key events ahead for DISCMAM

The gathering covered a broad range of topics, from management and dissemination updates to technical developments, with a particular focus on the progress of the digital solution for on-site process optimisation and the status of the integration between the digital and physical components developed so far. These discussions aimed to assess the feasibility of the combined solution and define the next steps towards its validation in real operational environments.

Participants had the opportunity to visit and tour the Center for Industrial 3D Printing at DTI — one of Denmark’s few facilities equipped with industrial 3D printers for both metal and plastic. The Center supports the full value chain, from concept and design to construction, optimisation, and pilot-scale production, ensuring the delivery of tailored technical solutions that align with DISCMAM’s objectives.

As the project enters a decisive year, DISCMAM will be showcased by its partners at key additive manufacturing and 3D printing events, including FORMNEXT – the industry hub for Additive Manufacturing (19–22 November 2025, Frankfurt, Germany) and the AM Village 2026 (16–20 March 2026, Albacete, Spain). The AM Village organised by EDA and Spain Air Force will represent a major milestone for the project, featuring a dedicated workshop focused on quality assurance and quality control methods in on-site metal AM for the defense sector, and a live on-site demonstration of the DISCMAM solution and its advanced capabilities in secure, on-site manufacturing of spare parts with a deployable system from our core partner Fieldmade.

Consortium partners visited the Center for Industrial 3D Printing, guided by the DTI team.

• Led by LORTEK and Accenture, the EDF-funded project has completed two major actions that reinforce its mission to deploy on-site metal Additive Manufacturing (AM) technologies for defence applications, showing significant progress beyond the mid-point of its development.

The DISCMAM project is progressing through a key phase of its development, marked by the successful completion of two strategic milestones. The first, led by Accenture, focused on the Cybersecure Digital Pathway solution, creating a secure digital framework for files and process data sharing that meets EU military platforms requirements and enable future digital part qualification without requiring additional on-site testing. The second, led by project coordinator Lortek, advanced the development of process monitoring systems and a defined manufacturing workflow, delivering an updated strategy for on-site operations that reduces system downtime while ensuring part quality and functionality of repaired or newly manufactured components.

A cybersecure digital pathway for DISCMAM solution

The completion of the Cybersecure Digital Pathway marks a major step forward in developing the DISCMAM secure digital framework, designed for seamless integration into multiple digital infrastructure scenarios.

The work, led by the consortium partner Accenture, aimed to ensure that all the components of the digital pathway (on-premises infrastructure, network architecture and cloud integration between others) adhere to robust security standards and EU military platforms compliance.

Smarter monitoring systems and optimized workflows

Under the leadership of Lortek, the milestone “Monitoring systems developed, and manufacturing workflow defined” has also been successfully reached, accomplishing several key objectives in the process.

Ensuring the quality, consistency and traceability of metal AM processes is at the core of this accomplishment. To this end, an extensive analysis of process monitoring systems/sensors in metal AM was carried out, addressing the limitations of traditional quality assurance methods and reviewing key in-situ process monitoring technologies currently used on powder bed fusion (PBF-LB/M) and directed energy deposition (DED-LB/M). To do so, common failure modes, and requirements for mobile AM in demanding environments were taken into consideration. A preliminary selection of complementary sensors was established to reliably detect critical defects under deployed conditions.

Building on this, the selected monitoring devices were integrated into AM equipment, enabling the first demonstrations of how real-time data can be captured and analysed to monitor melting or metal deposition processes. Two tailored approaches were developed for PBF-LB and DED-LB solutions, showcasing how monitoring strengthens quality assurance in different metal AM technologies.

Finally, a comprehensive maintenance workflow was defined for on-site operations, covering all stages from initial assessment and digital readiness to manufacturing, inspection, and final delivery. This workflow reinforces quality control through full documentation, rigorous real-time and post-process inspections, and secure management of digital files for complete traceability. Tested in real use cases, the approach has proven practical and effective, offering flexibility and efficiency for both repairs and the production of complex, low-volume components while ensuring high-quality, compliant outcomes.

The next steps of the project, involve the full integration of the developed solutions and systems to validate the DISCMAM solutions and approach, aiming at on-site repair and manufacturing as well as data information sharing under remote assistance through a secure digital pathway.

• ADAXIS is involved in the DISCMAM project, contributing to the “Digital solutions to accelerate on-site additive manufacturing” action, closely matching its goal of creating a seamless digital workflow for multi-axis robotic manufacturing including 3D scanning and Directed Energy Deposition (DED) processes.

The DISCMAM project is pioneering key innovations in metal additive manufacturing (AM) aimed at transforming defence logistics. Central to this initiative is the development of a complete, autonomous, and secure digital workflow that enables robotic repair operations even in the most challenging environmental conditions. Behind this effort is the young company ADAXIS, which integrates cutting-edge technologies within an intuitive and accessible software framework, playing a crucial role in advancing the project’s vision of deploying intelligent, field-ready manufacturing systems that enhance efficiency and resilience in defence operations.

AdaOne by ADAXIS: Software for robotic hybrid Manufacturing

ADAXIS is a robotics software company dedicated to enabling next-generation manufacturing by making industrial robotics accessible, intuitive, and scalable. The company’s mission is to empower industry stakeholders to adopt flexible and sustainable production processes through user-friendly digital tools.

Its all-in-one software, AdaOne, transforms conventional robotic arms into versatile, high-performance hybrid manufacturing units capable of additive manufacturing, subtractive machining, and inspection.

The ADAXIS team brings together a multidisciplinary group of professionals with deep roots in European research and extensive experience in manufacturing innovation in the defence sector, among others: Guénolé Bras (CTO), Emil Johansson (CPO), Sami Fadil (Application Engineer) and Romain Goffe (Lead Developer).

Commenting on the DISCMAM Project, Henri Bernard, CEO of ADAXIS, said:

“The DISCMAM project is a major leap forward in making hybrid manufacturing scalable and accessible. Contributing to the deployment of technology that enables direct, simple, and in-situ metal AM and repair is a technically fascinating challenge — it brings together part inspection thought 3D scanning, metal additive manufacturing and machining of large, complex parts in real-world conditions. This project is fully aligned with our mission at ADAXIS: simplifying advanced robotic processes through powerful, intuitive path planning software. We’re proud to be part of this dynamic and high-performing European R&D consortium”.

Advanced software suite for DED

As part of the DISCMAM project, ADAXIS leads the work package on “Digital solutions to accelerate manufacturing on site” directly aligning with its vision of an integrated, digital workflow for multi-axis robotic manufacturing. The focus of ADAXIS’s contribution lies in the development of a sophisticated software suite to enable semi-automated and fully automated tool path planning for on-site Directed Energy Deposition (DED) processes. Key innovations under development in the project include:

This toolset is designed to minimize post-processing, improve process reliability, and ensure compatibility with remote assistance protocols. Expert feedback will be embedded into the decision-making logic of the software, forming the basis for a robust set of heuristics tailored for in-field robotic manufacturing.

This effort aligns seamlessly with ADAXIS’s strategic goal of offering a unified digital environment for the design, simulation, execution, and monitoring of additive, subtractive, and inspection operations—delivering one of the most comprehensive CAM solutions for multi-axis manufacturing processes available today.

Global partnership fuels ADAXIS innovation

The founding team has a strong track record in managing complex, high-impact initiatives in prior roles. ADAXIS is currently involved in Sustainable Steel Additive Manufacturing (SESAM) (Vinnova 2022-01239), a project aimed at enabling serial production of large-scale parts using wire-laser DED, with industrial partners such as Alfa Laval and Procada. This international collaboration reinforces ADAXIS’s commitment to advancing metal additive manufacturing through cooperative innovation with LORTEK, DTI and other reference research centres in projects such as DISCMAM.