NCK MATCA 2 - DP Advanced Post-Processing of Metallic Components Using Laser and Electrochemical Methods

"The sub-project is motivated by the industrial need for advanced post-processing technologies that ensure the functional quality of both additively manufactured (AM) and conventionally produced metallic components. Surface roughness and fatigue resistance remain two of the main barriers preventing wider adoption of AM parts in high-performance applications such as aerospace, energy, and automotive sectors. Conventional polishing methods are often limited by poor accessibility to complex shapes and by the risk of removing material in critical areas such as thin edges. The project therefore focuses on the development and validation of three complementary advanced post-processing approaches: Laser Polishing (LP) combined with Laser Shock Peening (LSP) – a fully non-contact process enabling the treatment of complex, curved, and hard-to-reach surfaces with simultaneous improvement of surface integrity and fatigue life. This will be applied not only to AM parts but also to conventionally manufactured components where traditional polishing is ineffective. Electrochemical polishing (ECP) – building on previous project results, the aim is to further develop and prototype a dedicated electrochemical polishing device tailored for AM and conventional components. The device will ensure controlled surface roughness reduction without deformation of sensitive areas such as thin edges. According to the current demand from industry, the project will primarily focus on tool steel 1.2709, stainless steel, inconel 718 and titanium grade 5, but the results will remain open and applicable to other metallic materials."