The Italian companies Prima Additive and Comau have developed an innovative solution for the automated coating of brake discs. At the Stellantis Factory Booster Day in Turin, the companies presented a state-of-the-art system that uses dual-layer laser cladding to coat brake discs with resistant steel and composite materials. The aim is to increase the durability of the discs and at the same time reduce particulate emissions by up to 80 percent.
“At Prima Additive, we believe that collaboration and innovation are the driving forces shaping the future of manufacturing,” explained Paolo Calefati, CEO of Prima Additive. “Our collaboration with Comau joins two companies with deep expertise in their respective fields to develop a truly cutting-edge industrial solution in automation and advanced laser systems for material processing. More importantly, the laser system developed for the brake disc coating application is one of the most profitable and sustainable cases of laser additive manufacturing/laser cladding technology applied in mass production for automotive. This solution not only contributes to improving the performance and the durability of automotive brake discs, but it also plays a crucial role in promoting sustainability by reducing the overall environmental impact of motor vehicles.”
The system is based on a combination of advanced laser systems, high-speed robotics and additive manufacturing processes. Particularly noteworthy is the integration of Comau’s robotic arms with Siemens SINUMERIK Run MyRobot, which enables the robotic arm to be controlled directly via a standardized software platform. This reduces the dependency on additional control devices and ensures greater flexibility. The cells’ modular gripper tools can handle brake discs of different sizes – from cars to trucks – making the system adaptable to different production requirements. The solution is also characterized by energy efficiency and a small footprint.
“This robotized solution represents a great example of innovation, led by two Italian companies who have developed advanced technologies to meet important sustainability targets”, added Pietro Gorlier, CEO of Comau. “In working together to safely automate high-speed laser cladding, Comau and Prima Additive are helping meet a growing demand in Europe and beyond for flexible, turn-key solutions that will help reduce particle emission pollution in response to recent regulations. We are confident there is significant market potential for this type of solution.”
The system is expected to be installed at the Stellantis plant in Septfonds, France, by the end of 2024. Stellantis will thus be one of the first car manufacturers to introduce a fully automated production line for coating brake discs in line with Euro 7 standards.
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