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.

TheΒ Fraunhofer IPK Project Office for Advanced Manufacturing at 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.

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Material qualification for AM processes

πŸ“„ Qualification of CuCr1Zr for laser power bed fusion
Comeback of cooper in toolmarking

 

Economical and technical feasibility of AM applications

πŸ“„ Metal additive manufacturing
Laser powder bed fusion and directed energy deposition

πŸ“„ Expert Survey – AM Trends 2020
Future services and products of additive technologies

πŸ“„ Fast prototype
Additive manufacturing as a tool in development projects

Product optimization – Design for AM

πŸ“„ Hybrid design of additive components
Combining different AM technologies for product and process optimization

πŸ“„ AddiCut
Additive manufacturing of an optimized milling tool

πŸ“„ AM Gears – Additive manufacturing of metalpolymer gears for automotive transmissions
Development of metal-polymer composite gears manufactured by additive manufacturing

AM Process development

πŸ“„ AGENT_QualiPro
Quality management for safe and robust additive production

πŸ“„ Monitoring distortion and cracks during additive processes
Equipment development with in-situ residual stress measurement

πŸ“„ Additive Manufacturing 4.0
Mobile App for Quality Assurance

πŸ“„ Quality management in the additive production
Development of quality routines along the additive process chain

πŸ“„ Numerical simulation of additive processes
Optimizing heat flows and reducing dimensional deviations

πŸ“„ 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

πŸ“„ Lightweight Components for Large Jets
From AM process design to finished prototypes

πŸ“„ ProFex
Process chain for the manufacturing of highly complex turbine components

πŸ“„ 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

πŸ“„ Post-processing of TI6AL4V Preforms Manufactured by Wire Arc AdditiveManufacturing (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

πŸ“„ Automatic optical inspection of glass tubes
Optical inspection for continuous quality assurance

πŸ“„ 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

How to cooperate with us

A step-by-step guide
  • Company approaches the Fraunhofer IPK Project Office for Advanced Manufacturing at ITA with an inquiry
  • Definition of project scheme
  • The international team of experts, together with the company, discuss and defines and the project scope, demands and requirements
  • Our team proposes the best contract model for hiring the Fraunhofer IPK Project Office at ITA, which depends on the division of work and financing source
  • A proposal is developed by our team
  • The contract between the parties is prepared and the company places the order (non-disclosure agreements can also be prepared in parallel)
  • We carry out the project
  • Presentation of results upon project completion

Contact

Prof. Dr. Ronnie Rego

Head of Operations Fraunhofer IPK Project Office for Advanced Manufacturing at ITA

Phone: +55 12 3947-6948
E-Mail

Dr.-Ing. David Carlos Domingos

Head of Operations Fraunhofer IPK Project Office for Advanced Manufacturing at ITA

Phone: +49 30 39006-413
E-Mail