Wiesbaden, Hesse, Germany
I specialize in metal additive manufacturing, a field that I am passionate about and driven to optimize. My research focuses on developing and improving laser metal deposition (LMD) processes for large components in the aerospace and oil and gas industries, using advanced monitoring and control systems to enhance productivity, efficiency, and sustainability. With more than 5 years of experience in process development and engineering, I have led and contributed to numerous multidisciplinary projects that have shaped the field. For example, I developed a novel LMD process for gas turbine components that achieved a 5x increase in productivity and a 50% improvement in environmental performance compared to standard conditions. I also explored and assessed commercial solutions and suppliers for LMD systems and devices, and designed and installed optical process monitoring and control systems on the LMD machine. Additionally, I have taught and tutored students in manufacturing technology courses at Politecnico di Milano and other institutions, sharing my knowledge and enthusiasm for the field.
EHLA process and applications development
- Conducted research on Laser Metal Deposition (LMD) of Ti6Al4V Ti-alloy in an inert environment for the A.dditive MA.nufacturing T.iltrotor HO.using project. - Investigated health-related issues caused by nanoparticles released during the LMD process using both powder and wire feedstock. - Explored LMD for Civil Engineering applications as part of the EU-RFCS CONSTRUCTADD project. - Developed LMD CAM programming and process for the realization of large components using wire feedstock. - Co-supervised multiple thesis works on Metal Additive Manufacturing related themes. - Published five peer-reviewed scientific papers in international journals. - Presented at two international industry and scientific conferences, including the Laser in Manufacturing Conference 2023 in Munich.
Course: Manufacturing Tehnology I - BSc in Mechanical Engineering (2nd year) Topics: material science, casting, shell molding, milling, turning, drilling, forging, sheet lamination, extrusion, stamping, process optimization. Tasks: front lectures, tutoring activities, written and oral examinations of students.
Course: Advanced Manufacturing Processes Laboratory - MSc in Mechanical Engineering (5th year) Topics: material characteriazation, metrology, laser manufacturing processes, laser cladding, design of experiments. Tasks: front lectures, tutoring activities, laboratory activities management.
Direct Energy Deposition and Hybrid Manufacturing group - Supported multi-axis Laser Metal Deposition (LMD) and machining operations, ensuring smooth and efficient production processes. - Conducted troubleshooting activities for LMD processes, identifying issues and possible solutions to maintain optimal production performance.
External industrial PhD researcher with Politecnico di Milano Principal results: - Developed a Metal Additive Manufacturing process (Laser Metal Deposition, LMD) for large Gas Turbine components. - Achieved a 5x increase in productivity for the LMD process compared to standard conditions. - Implemented improvements to enhance the efficiency and sustainability of the LMD process, resulting in a 50% improvement from standard conditions. - Designed, assessed, and installed optical process monitoring and control systems on the LMD machine (First Time Right, FTR). - Explored commercial solutions and suppliers for novel LMD systems and monitoring devices. - Assessed the performance of robot and CNC LMD machines, including their respective CAD/CAM software, identifying potential cost savings of up to 4x for future equipment investments. - Diagnosed and resolved issues across the LMD process, including troubleshooting and debugging of PLC systems, machine components, and process-related challenges. - Created C-based automated code for streamlined generation of machine G-codes, simplifying the process for employees and reducing manual effort while minimizing the risk of coding errors.
Executive track “Manufacturing Management Industria 4.0” Lecturer of the Metal Additive Manufacturing modules: - Directed Energy Deposition - Powder Bed Fusion