As part of the ESMA project, a technology platform for integrating sensors into products is being developed. The method used is 3D printing, also known as additive manufacturing. In this process, material is applied layer by layer within a 3D printer until the desired structure is created. The process is already highly advanced and is used for prototyping, increasingly for small-scale series production, and in some cases even for large-scale production. However, the development of smart components with integrated sensors is still in its infancy.

During the project preparation phase, numerous discussions were held with various stakeholders, including industry representatives, scientific partners, clinics, and the Carinthian Economic Promotion Fund (KWF). It was conveyed to us that the development of sensorized components presents a significant challenge but is worth overcoming. Behind this effort lie considerable economic opportunities, while the social and ecological impact of the ESMA project is also highly relevant.

The realization of the project involves a series of technological challenges. First, it must be ensured that the integrated sensors function flawlessly and that the other component properties, such as mechanical characteristics, are not adversely affected. Second, it must be guaranteed that the sensors enable data transfer to external systems. Third, it must be ensured that the sensors can be embedded at any location and in any spatial orientation, including inclined or twisted positions. Since conventional 3D printing methods are not capable of achieving this, we propose the multi-axial 3D printing process as a solution.

In addition to technology development, achieving rapid market access is important to us. To this end, it is necessary to provide future users, such as engineers and designers, with a tool to utilize the new ESMA technology in their daily practice. To solve complex design tasks, we are extending the well-known TRIZ method to include the capability of effectively integrating sensors.

Demonstrating the advantages of the technology is crucial for post-project technology diffusion. For this reason, impact cases have been developed to showcase the potential of the ESMA technology in improving the quality of life for vulnerable groups and women. Additionally, it will be demonstrated how ESMA technologies can be used to promote greener production.

The project design is structured in such a way that follow-up projects will serve as meaningful extensions. Within the ESMA project, the technology platform will be developed. In subsequent projects, use cases for various applications will be developed in collaboration with industry partners.