ProjectRECOR

Surface functionalisation using ultrashort pulse lasers opens up major prospects for many industrial applications: improved tribological properties, adhesion control, friction reduction and optimised functional performance.

However, when it comes to processing large surfaces or complex geometries, a major technological barrier arises: the part cannot be processed in a single pass.

The process must then work in successive zones, called patches, corresponding to the laser scanner field. The challenge becomes critical: ensuring perfect continuity between these zones, with no visible defects, no overheating and no alteration of properties.

Existing methods do not currently allow sufficiently precise and dynamic registration between these zones, particularly in industrial environments.

The RECOR project aims to overcome this barrier by developing advanced localisation and dynamic registration solutions combining robotics, optics and laser control, to enable uniform texturing of large surfaces.

24-month project, from 1 January 2025 to 31 December 2026

The RECOR project aims to make laser texturing of large surfaces reliable and industrially viable through precise positioning control.

Its objectives are to:

• Develop a solution for precisely locating already-textured zones
• Design a dynamic registration system enabling repositioning at micrometre scale
• Control the laser head to ensure perfect continuity between treated zones
• Optimise patch size and positioning to guarantee uniform treatment
• Integrate these solutions into a representative industrial machine
• Achieve accuracy levels compatible with industrial requirements (down to ±10 µm)

The ultimate goal is to move from proof of concept to a solution close to industrialisation (from TRL 2-3 to TRL 5-6).

• Accurately detect already-textured zones, despite the low visibility of the patterns and the constraints of the instrumentation and acquisition conditions
• Ensure precise repositioning of textured zones by compensating for the limited absolute accuracy of industrial robots through a closed-loop control strategy
• Combine robotic positioning and fine control of the laser head, using a “macro/micro” approach, to guarantee precise juxtaposition of textured zones
• Adapt the laser process to the actual tolerances of large industrial parts, rather than imposing manufacturing requirements incompatible with industrial capabilities

The RECOR project is conducted within a LABCOM (joint laboratory) combining industrial expertise and academic research:

• IREPA LASER – Project coordinator, development and integration of solutions
• ICube Laboratory
  • RDH team (Robotics, Data Science and Healthcare Technologies)
  • IPP team (Instrumentation and Photonic Processes)

The RECOR project paves the way for a new generation of industrially viable laser texturing processes.

Reliable large-surface texturing processes
Dynamic registration ensures perfect continuity between zones, guaranteeing uniform quality with no visible defects.

Access to large, complex parts
The solutions developed make it possible to process parts that were previously difficult, or even impossible, to texture reliably.

Improved precision and repeatability
Integrating robotics and optical control makes it possible to achieve accuracy levels compatible with industrial requirements.

Faster industrial transfer
Reaching high technology readiness levels (TRL 5-6) facilitates rapid integration of the solutions into industrial environments.

Strengthened expertise in advanced laser processes
The project consolidates IREPA LASER’s skills in surface functionalisation, robotics and the control of complex processes.