The SinglePAM, NEXT and SKIN Pro projects were carried out from 1 January 2018 to 31 March 2023 under the auspices of the German Aerospace Research Programme. The consortium consisted of Access e.V. in Aachen and Hanseatische Waren Handelsgesellschaft mbH & Co. KG in Bremen, with Dr. Ing. Rüdiger Tiefers serving as project leader. The funding was provided through the Lufo programme, which supports advanced research in titanium‑aluminium alloys for aerospace applications. The overarching aim was to close the entire alloy supply chain for γ‑TiAl turbine blades, from alloy design and casting to recycling, and to elevate the manufacturing routes to Technology Readiness Level 6. The project also integrated Industry 4.0 concepts to enhance process monitoring and data analytics.

Technically, the work began with the definition of a comprehensive process route for the production of TiAl blades (AP 1.1). This involved establishing the sequence of alloy preparation, melting, casting, and post‑processing steps that would meet the stringent certification requirements of the aviation sector. Subsequent work packages focused on validating the feasibility of this route through casting simulations (AP 1.2). The simulations revealed a strong correlation with experimental results for a 120 mm die produced by the ALD process at HWH, confirming the reliability of the modelling approach. Earlier simulations of the RETECH process, however, showed discrepancies due to unknown process parameters, underscoring the importance of accurate input data.

The design of a continuous casting die (AP 1.3) was led by HWH and supported by Access. Detailed tooling concepts for the γ‑TiAl casting electrodes were developed, and the geometry of both the melt pot and the die was finalized. The plant concept (AP 1.4) was then laid out, with a production layout presented for the Bremen site. This layout incorporated a hydraulic press for compacting raw material, a dedicated melt pot, and the continuous casting die, forming a streamlined production line. The integration of these components enabled a closed‑loop process that could handle both primary alloy production and secondary recycling streams.

Further experimental work (AP 2.1–2.6) involved the construction and commissioning of the PAM melting plant, the execution of melting trials to define process parameters, and extensive material investigations to assess the mechanical properties of the cast blades. The trials confirmed that the process parameters derived from simulation could be reliably reproduced in practice, and the material tests demonstrated that the produced TiAl blades met the required strength and fatigue performance criteria. The validation of the casting simulation (AP 2.6) was a key milestone, as it provided confidence that future scale‑up could proceed without significant risk.

The final phase (AP 3.1–3.2) produced and qualified turbine blade components using the developed routes. The blades were fabricated for both conventional engines such as the XWB, LEAP, and GenX, and for high‑pressure fan applications like the GTF and Ultrafan. The successful qualification of these components at TRL 6 marked the transition from research to industrial readiness. Throughout the project, the consortium maintained close collaboration with external partners, including suppliers of alloy materials and certification bodies, ensuring that the developed processes aligned with industry standards and regulatory requirements. The project’s outcomes provide Access with an independent alloy supply chain, a robust recycling pathway, and a demonstrably efficient, Industry 4.0‑enabled manufacturing process for certified γ‑TiAl turbine blades.