The core of the use case approach is the CLASCO machine, which combines laser polishing and laser surface texturing as consecutive post-processing steps for additively manufactured metal parts. Each of the five demonstrators follows the same workflow: the required surface function was derived from the application, a representative component was selected, and the conventional finishing route is benchmarked against the new CLASCO manufacturing process chain. The machine itself is designed to be a digitalised platform for in-line monitoring and data-driven parameter control, incorporating AI-supported methods to stabilise quality and improve process efficiency. By consolidating finishing operations within a single system and reducing the need for iterative trial and error, this approach also aims to make post-processing more sustainable by reducing material waste and improving energy efficiency.
The medical demonstrators include a knee implant femoral component and a trauma plate. For the knee implant, the aim is to achieve low friction as well as enhanced adhesion, or osseointegration. The baseline is casting in a cobalt-chromium alloy, whereas CLASCO proposes additive manufacturing using Ti6Al4V. For the bone healing trauma plate, the objectives are controlled cell adhesion and antimicrobial properties. This involves comparing the conventional machining of Ti6Al4V with the additive manufacturing of the same alloy.
In space, the demonstrator is a payload clamp band for a satellite separation mechanism which aims to reduce and control friction. CLASCO replaces the conventional machining of an aluminium alloy with the additive manufacturing of Scalmalloy (AlMgSc), achieving a 25 per cent reduction in weight.
In the field of aviation, CLASCO specialises in two components for the A350: a media nozzle actuator bracket and a media nozzle actuator lever. These components are transitioning from being CNC-machined from Ti6Al4V to being additively manufactured from Scalmalloy. The bracket is designed to offer enhanced corrosion resistance and hydrophobic properties, and is associated with a 53 per cent reduction in weight and improved cost efficiency. The lever features a surface designed to enhance tissue adhesion and has been reduced in weight by 38 per cent.