Introduction
GRADEL, a company with a rich history spanning 60 years, has been a stalwart in developing maintenance, handling, and filtration systems for nuclear power plants. This strategic business field is experiencing a renaissance today. Over the years, GRADEL diversified into producing sputtering targets for the glass industry and, in 2010, ventured into the space market with Mechanical Ground Support Equipment. However, the globalization of markets and the outsourcing of supply chains to Asian countries, coupled with increasingly complex demands, led to severe pressure on margins in Europe until 2020. This situation has been further exacerbated by the current geopolitical climate.
Recognizing the Need for Innovation
In 2019, GRADEL foresaw these challenges and embarked on a radical innovation journey with the development of the GRAM process technology. GRAM, which stands for Gradel Robotic Additive Manufacturing, is a continuous fiber winding process that allows the creation of complex 3D structures using various fiber materials such as carbon, basalt, glass, and hemp. The fibers are impregnated with a resin system on the GRAM winding head, which is manufactured in-house. This AI-supported digital process chain enables a single mechanical engineer to develop a component from start to finish, including robot programming, without needing to be a specialist in FEA or robot programming. This innovation drastically reduces development costs and achieves bionic structures with up to 70% weight savings, without compromising on strength, stiffness, and natural frequency behaviour.
Strategic Goals and Market Establishment
GRADEL's strategic goal is to establish the GRAM process technology in the market and make it a reference process. As a mechanical engineering company, GRADEL has the opportunity to commercialize its own product, protected by patent. The company aims to shift from 70% project business and 30% product business to a model where product business constitutes up to 85% of its operations. Rather than mass production, GRADEL focuses on manufacturing and distributing targeted products with high added value in small and medium quantities, focusing on customization.
Partnership with Data Design Engineering
A key partner in this transformation is Data Design Engineering (DDE), also based in Luxembourg. DDE's primary task at GRADEL is to train the models and algorithms of the GRAM-AI software, considering design and feasibility rules and the process parameters required during winding. Despite resistance from the aerospace, automotive, and other industrial sectors to adopt new manufacturing methods, DDE has developed an Offline Large Multi-Model on Edge Device software. This compact software allows complex systems to be used exclusively via cloud, GPS, or local networks, enabling new applications to control edge devices without relying on satellite-based networks.
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How innovation can help transform a project-based business into a product-based one. Perseverance is key, as there are multiple internal and external hurdles to tackle
Lightweight Construction: A Game Changer
Lightweight construction, a significant aspect of GRAM technology, starts with software. Optimally programmed algorithms that require minimal computing capacity result in smaller cooling fins to dissipate heat and lighter batteries. When GRAM lightweight technology is applied to the brain of a machine, the result is a lightweight system. The combination of GRAM and DDE's technologies is currently unmatched and available worldwide exclusively through these two partners. Applications range from drones and autonomous driving systems to service robots, humanoids, and voice-controlled wheelchairs.
The Journey and Future Prospects
The journey from idea to finished product was long and challenging for GRADEL, but it demonstrated the value of perseverance. The company is now in the final phase of industrialization and actively seeking investors to scale up. With three international joint ventures in the pipeline, the success story of GRADEL's lightweight innovation is set to exceed expectations, despite taking longer and requiring more financial resources than initially anticipated.
A special thank you goes to all GRADEL employees, whose dedication made this remarkable transformation possible.
Conclusion
GRADEL's innovative approach with the GRAM process technology is a testament to the company's commitment to transforming from a project-based to a product-based business. By leveraging cutting-edge technology and strategic partnerships, GRADEL is poised to lead the market with high-value, lightweight products that meet the demands of modern industries.
