TECNALIA at BIEMH 2026: The Power of the Proactive Factory

AI that finds similar plans and accelerates technical decisions.

Solution developed with AMETS, specialists in precision machining tools and tooling.

A visual AI-based tool that identifies similar plans, automatically extracts dimensions and detects relevant views using Vision-Language models.

Value generated

• Bidding and process preparation times are reduced.
• Re-use of previous programming.
• Centralisation of dispersed knowledge, facilitating generational succession.
• Traceability and efficiency in environments with thousands of plans.

The platform that keeps vision intelligence alive in the factory.

Solution developed with IDEABLE on an ACEROS OLARRA use case.

A tool that centralises the life cycle management of vision models: retraining, updating, monitoring and deployment of models without the need for deep learning specialists.

Value generated

• Maintains the adaptive factory: AI evolves with real production.
• Avoids degradation of the model due to changes in material or conditions.
• Empowers technical staff without AI profiles.
• Generates synthetic defects that enrich AI capabilities

The virtual factory that tests scenarios before running them.

Solution developed with SmartPM, experts in industrial process optimisation.

An operational twin of the environment depicted on the stand that models machines, AGVs, robots and people, enabling sequences to be planned and complex scenarios to be simulated before making decisions.

Value generated

• Reduces the implementation costs of improvements.
• Enables changes to be validated in a secure virtual environment.
• Improves overall awareness of the plant.

Simulation and offsetting for more precise and more controlled machines.

Solution developed with NICOLÁS CORREA, MTORRES, IBARMIA.

A multidisciplinary approach to understanding, predicting and offsetting thermal deformations that affect the precision of machine tools.

Value generated

• 75% of machine inaccuracy is of thermal origin.
• Critical deviations can be corrected.
• Machining accuracy is increased.

From concept to validation: we turn ideas into real prototypes.

Solution developed for IBARMIA, a reference in the manufacture of machining centres.

A new range of machines that enables IBARMIA to offer a competitive solution that fully machines the part, without the need to use the C-axis.

Value generated

• Programming is considerably simplified and the machining process is optimised
• Increased turning capacity.
• Greater flexibility and production capacity.
• Competitive solution thanks to the specificity of the solution compared to brands by general lathe manufacturers.

AI proposes, evaluates and optimises designs in minutes.

An autonomous tool capable of generating optimised preforms for blow moulding processes, evaluating them with physical simulation and selecting the most promising candidates.

Value generated

• Reduction in design time.
• Expert knowledge capture (key to generational succession).

Simulation that enables the quality of the gears to be seen and optimised before the first cut.

Solution developed with IBARMIA, a benchmark in the manufacture of machining centres.

Advanced simulation that enables the Skiving process to be visualised and how the different machining errors influence the final quality of the gears to be analysed, such as run-out, tool wear, tool-workpiece alignment, part distortions or misalignments in the machine axes.

Value generated

• Increased process reliability prior to manufacturing.
• Reduced technical and commercial risk in tenders.
• Accelerated decision-making for customer and manufacturers.
• Increased final quality of the gear and facilitated process validation.

Quantum Computing to solve the three-dimensional packing problem

This solution, developed with Würth in collaboration with Telefónica and QCentroid, is an industrial use case with real data that applies quantum and hybrid (quantum + classical) computing to solve the challenge known as 3D Bin Packing: how to place items in boxes in order to use as few boxes as possible per order, improving the use of space and reducing logistical inefficiencies.

Challenge solved

Preparation and dispatch operations with:

• Thousands of references (tools, fasteners, consumables).
• Irregular items (loose screws + bulky drills in a single order).
• Packaging decisions with direct impact on cost, time, transported volume and sustainability.
• Very advanced classical systems, but with room for improvement in complex combinatorial scenarios.

Solution

• Determination of the box selection and the optimal 3D arrangement of items per order.
• Minimisation of used boxes and reduction in air transported (better filling).
• An actionable recommendation for the operation is generated:
  • recommended box(es)
  • 3D distribution
  • alternatives according to rules (fragility, priority, speed, robustness)

Use case: Würth (actual data, industrial approach)

Project aimed at real B2B order preparation and dispatch operations with a wide variety of references and formats.

Aim: assess whether new quantum and hybrid algorithms offer measurable improvements over manual/heuristic approaches for certain order profiles.

Key development partners:

• Telefónica – Key partner in the development and promotion of the solution, guiding the industrialisation, integration and landing of the use case to a model applicable in real operation.
• Würth – Industrial use case, real data, operational validation and efficiency/sustainability targets.
• TECNALIA – Reference technology centre in applied quantum computing; implementation of quantum and hybrid solvers (including D-Wave technology) and specialised research support.
• QCentroid – Partner in the quantum ecosystem in Spain, accompanying the development and scaling vision.

Impact potential (claims to be validated with the use case)

Operational efficiency:

• Potential reduction in the number of boxes per order.
• Potential improvement in volumetric use (fewer voids).

Logistics costs:

• Potential reduction in packaging costs.
• Potential reduction in transport costs due to better consolidation (pallets/trucks).

Speed and quality:

• Potential for increased consistency in packing decisions.
• Potential reduction of rework/inefficiencies associated with sub-optimal packaging.

Sustainability:

• Potential reduction in cardboard consumption/fillers and reduced footprint associated with shipping.

A connected environment that reproduces real manufacturing situations to show how a truly proactive factory behaves.

Here, the machine understands, interprets and acts before problems arise.

In this machine tool demonstrator, it can be seen how the system:

• Understands the geometry of the parts.
• Adapts paths in real time.
• Monitors their state of health.
• Corrects deviations automatically.
• Interacts via voice and intelligent assistants.
• Connects machining, repair, maintenance and control operations in a single coherent flow.

It is a tangible representation of more conscious, flexible and collaborative manufacturing: The Proactive Factory brought to machine tools.

Measurement cycle and path adjustment

Solution developed with IBARMIA, a benchmark in the manufacture of machining centres.

Measurement of the dimensions on the machine and real position of the workpiece, enabling the actual machining path to be adjusted and optimised.

Value generated:

• Avoidance of dry runs and possible collisions.
• Increased process reliability.
• Increased productivity
• Reduction in errors resulting from imperfect part positioning.
• Facilitation of machining of parts from casting, forging and/or additive manufacturing processes.

Recovery or functional improvement of critical metal components by hybrid manufacturing

Methodology that extends the service life of components.

Hybrid manufacturing technology (Additive Manufacturing DED + Machining) assisted by artificial vision and CAM automation techniques to recover metal components or improve mechanical properties in areas of interest, extend their life and reduce costs.

Value generated:

• Waste minimisation.
• Contribution to reducing the carbon footprint.
• Reduction in replacement or recovery costs.
• Increased operational efficiency.
• Facilitation of learning for the operator.
• Reduced dependence on the expert operator.

Voice control for machine tools

The natural interaction that brings the machine closer to the person.

Spoken commands to run operations, query status or adjust parameters with simplified and accessible human-machine interaction.

Value generated:

• Increased productivity
• Reduced human error.
• Improved collaboration.
• Machine is more accessible.

Control of vibrations in machines and manufacturing processes

Control of vibrations The key to precise and productive manufacturing

Solution developed with MTORRES, , a reference in innovative solutions for industrial processes.

Dynamic monitoring to anticipate instabilities, guarantee the precision of paths and avoid defects in the machined parts.

Value generated:

• Increased quality of the manufactured parts.
• Reduced unscheduled downtime due to mechanical failures.
• Service life of the machines is extended.
• Rejection costs are minimised.

Rotary table diagnostics

Intelligent inspection that guarantees quality.

Solution developed with ZEATZ, specialists in the customised design of rotary tables and turntables.

Automated analysis of the condition of the rotary table to ensure quality, performance and durability.

Value generated:

• Avoidance of errors in critical operations.
• Increased confidence in the process.
• Greater traceability.
• Reduced verification times.
• Prevention of faults and unwanted machine downtime.

Machine Health Status (Fingerprint)

The fingerprint that reveals the status of the machine at any given moment.

Solution developed with IBARMIA, NICOLAS CORREA and SHUTON, references in machine tools.

Continuous comparison between actual and reference behaviour to identify anomalies and prevent failures.

Value generated:

• Faults anticipated before they occur.
• Increased availability of the machine
• Reduced maintenance costs
• Increased operational efficiency.

Tool management system

Control of the tool and quality of each part.

A system that monitors the actual use of tools links process parameters and ensures that each operation is performed under optimal conditions.

Value generated:

• Quality of the final part is guaranteed.
• Tool life is increased.
• Deviations that are invisible to the operator are avoided.
• Greater traceability in critical processes.

Smart welding and autonomous additive manufacturing

An advanced solution combining robotic hardware, intelligent process monitoring and specialised software. A customised graphical interface, adapted to each operation. A system that adjusts parameters in real time. And AI that guides welding and additive manufacturing, even without prior experience.

Value generated:

• Programming is facilitated with integrated AI.
• Increased accuracy and efficiency.
• Accessibility to non-experts.
• Production of complex parts is simplified.

Watch the video on how smart welding and autonomous additive manufacturing are transforming production.

A smart system combining robotics, advanced sensing and industrial connectivity.

Designed to automate the disassembly of batteries and complex equipment.
A safe, flexible and efficient solution for the transition to the circular economy.

Value generated:

• Quick reconfigurations on battery disassembly and/or recycling lines.
• Human-robot collaboration is facilitated and risks for the operator when handling batteries are reduced.
• It automatically adapts to the battery model and its state of arrival.
• It accelerates the recycling and revaluation of resources.

Watch the video on how this smart system optimises battery disassembly, boosting the circular economy.

A humanoid robot that learns to perform tasks autonomously using reinforcement learning (RL) and imitation learning (IL).

It reproduces human gestures and learns by working with people, adapts its movements to the environment and performs logistical tasks that go beyond the capabilities of a conventional robot.

Thanks to the integration with real tooling and containers provided to the research by Gestamp, the humanoid is capable of:

• Handling complex parts with precision and line-specific logistics elements.
• Collaborating with the AGV, coordinating the delivery and collection of the parts received.
• Adjusting its behaviour according to the actual plant flow.

Value generated:

• Increased talent, where each person multiplies their impact in terms of efficiency and productivity.
• Different types of parts are handled with the necessary dexterity to work in complex environments, supporting repetitive human tasks.
• Safe interaction with the AGV, picking up and depositing loads in sync with the autonomous vehicle.
• Visual incidents, anomalous conditions or incorrect states in the intralogistics flow are detected.
• Versatility: it adapts tasks, learns variations and integrates into processes in which the combination of strength, precision and perception is key.

Solution developed in conjunction with TrebezIA, an expert in intelligent mobile robotics for the automation of complex intralogistics operations.

An autonomous robot that combines AI, advanced perception, navigation and manipulation to operate safely in dynamic and unstructured spaces.

Value generated:

• Automation of complex intralogistics processes.
• Increased agility and efficiency in tasks, such as order picking, loading and unloading.
• Autonomous operation in living spaces, shared with people and other robots.
• Seamless connection with the internal mobility ecosystem.

Solution developed with TECNALIA's #InnovativeAirMobility Lab.

An omnidirectional aerial robot designed for industrial inspection and maintenance in areas that are difficult, dangerous or directly inaccessible to a person.

Value generated:

• Access to complex areas: heights, inside tanks, energy, aeronautical, naval or petrochemical structures.
• Drastic reduction in occupational risk by eliminating work at heights and manual handling in hostile environments.
• Elimination of prolonged downtime and high costs, avoiding the assembly of scaffolding, cranes or lifting platforms.
• Performance of ultrasonic inspections without scaffolding, without cranes and without exposing an operator.
• Simplified predictive maintenance on critical assets.

See the video on how TECNALIA's omnidirectional aerial robot optimises inspections and industrial maintenance in hazardous environments.

The vehicle that closes the internal logistics circle.

An autonomous vehicle that transports materials between different points in the factory, integrated into The Proactive Factory ecosystem.

Value generated:

• Guaranteed continuous flow of materials.
• Reduced costs and travel times.
• Increased operational efficiency.
• The factory is connected internally, including with external points linked to customers or additional processes.
• It is characterised by its versatility and agility in logistical operations.