Additive Manufacturing

In recent years, additive manufacturing processes have been established in many areas of application. Layer-building processes have become the key to short development times and an economical manufacturing system for complex component geometries and small to medium batch sizes. Additive manufacturing (AM) processes serve an ever broader range of applications.

Originally only known to research institutions, additive manufacturing technologies are now increasingly applied in the aviation industry, toolmaking and the automotive industry in order to strengthen production.

The FPC@ITA has an expertise in three key technologies: selective laser melting (SLM), selective laser sintering (SLS) and 3D printing. Many metallic alloys and plastics can be safely processed and used for application fields from individual production to small series production. Components created on the basis of 3D CAD data can compete with conventionally produced goods in terms of material properties. In addition, tool-free production offers enormous advantages and added value in today’s production landscape.

Material qualification for AM processes
©Fraunhofer IPK ©CCM-ITA
Qualification of CuCr1Zr for laser power bed fusion

Comeback of cooper in toolmarking

Economical and technical feasibility of AM applications
©Fraunhofer IPK ©CCM-ITA
Metal additive manufacturing

Laser powder bed fusion and directed energy deposition

Expert Survey – AM Trends 2020

Future services and products of additive technologies

Fast prototype

Additive manufacturing as a tool in development projects

Product optimization – Design for AM
©Fraunhofer IPK ©CCM-ITA
AddiCut

Additive manufacturing of an optimized milling tool

Additive manufacturing for measuring devices

Homogeneous temperature fields via complex internal heating channels

Hybrid design of additive components

Combining different AM technologies for product and process optimization

AM Gears – Additive manufacturing of metalpolymer gears for automotive transmissions

Development of metal-polymer composite gears manufactured by additive manufacturing

AM Process development
©Fraunhofer IPK ©CCM-ITA
AGENT_QualiPro

Quality management for safe and robust additive production

Monitoring distortion and cracks during additive processes

Equipment development with in-situ residual stress measurement

Additive Manufacturing 4.0

Mobile App for Quality Assurance

Quality management in the additive production

Development of quality routines along the additive process chain

Numerical simulation of additive processes

Optimizing heat flows and reducing dimensional deviations

Influence of Machine Control and Dynamics on the Definition of Deposition Strategies and Travel Speeds for Laser Metal Deposition (LMD) Processes

Determination of a set of guidelines for trajectory generation in additive manufacturing (AM) processestowards the predictability of bead morphology

Pre- and post-processing for AM products
©Fraunhofer IPK ©CCM-ITA
Lightweight Components for Large Jets

From AM process design to finished prototypes

ProFeX

Process chain for the manufacturing of highly complex turbine components

FERA Feasibility Study - Tools and Gears Repaired Additively

This feasibility study aimed to explore the challenges of additive manufacturing application for gear teeth repair and the evolution to a robust design

Post-processing of TI6AL4V Preforms Manufactured by Wire Arc Additive Manufacturing (WAAM)

Evaluation of the relevant aspects for the integration between additive and subtractive manufacturing process of Ti6Al4V walls produced by Wire Arc Additive Manufacturing

AM surface integrity characterization
©Fraunhofer IPK ©CCM-ITA
Automatic optical inspection of glass tubes

Optical inspection for continuous quality assurance

FERA Feasibility Study - Tools and Gears Repaired Additively

This feasibility study aimed to explore the challenges of additive manufacturing application for gear teeth repair and the evolution to a robust design