Fraunhofer Institute for Casting, Composite and Processing Technology IGCV
Fraunhofer Institute for Casting, Composite and Processing Technology IGCV

Additive manufacturing (AM)

What is additive manufacturing?

Additive manufacturing (AM) - also referred to as 3D printing - is an emerging and innovative manufacturing process that differs fundamentally from conventional manufacturing processes and opens up new possibilities for research and industry. Components are built up layer by layer and are not created by removing material (for example, by milling) as in conventional processes. This results in enormous flexibility and design freedom, such as in the production of prototypes and increasingly in series production.    

Additive manufacturing at Fraunhofer IGCV

Additive manufacturing represents a strong cross-sectional competence of Fraunhofer IGCV. Currently, about 30 scientists are doing research in additive manufacturing processes. Due to the interdisciplinary orientation of additive manufacturing, three main areas of work have emerged:

Contact at Fraunhofer IGCV: Dr.-Ing. Georg Schlick

Additive Manufacturing at Fraunhofer IGCV: additive manufacturing experts

Additive manufacturing processes for industry

The research work focuses on the process technologies of additive manufacturing processes along their process chains. Also, methods for the product development of additively manufactured components are being developed, geared towards sensor-integrated multi-material components. For industrial implementation in production, Fraunhofer IGCV researches suitable methods of factory planning.

For this purpose, we have internationally recognized core know-how in the following processes:

Laser Beam Melting (also for the production of multi-material components)

As well as being used in prototyping and toolmaking, additive manufacturing processes are also increasingly being used in series production today. Powder bed-based laser beam melting is particularly suitable for the series production of metallic components.

In this process, the component is built up layer by layer by locally melting the metal powder using a laser beam and then solidifying the material. The advantages of the technology include the ability to create components directly from the CAD model, almost unlimited shaping freedom and high resource efficiency, as unmelted powder can be reused for subsequent production processes.

However, the temperature gradients that occur during the process result in deformations and residual stresses, which can have a negative impact on process stability and component quality.
This special feature of laser beam melting must be taken into account as early as the component design and production preparation stage. Examples of this are the stair-step effect, which influences the appearance and performance of the component, and the process-related need to build supports or support structures together with the component.

Binder Jetting

In the binder jetting process, powder material is solidified layer by layer through the local, precise introduction of a binder material via print heads with several 10,000 openings.

At the Fraunhofer IGCV, binder jetting is being investigated for the production of molds and cores for foundry technology, among other things (e.g. in the ConMon3D project). The focus here is on the processing of foundry-relevant materials, such as molding sands. We are researching different combinations of molding sands and binder materials that behave particularly economically and technologically favorably in casting processes. This can complement conventional production technology and thus act cooperatively as an enabler of improved (shortened) process chains in the foundry.

However, binder jetting does not only play a role in the field of sand-based additive manufacturing at the Fraunhofer IGCV. Steels and hard metals are also produced using metal binder jetting. As a sinter-based AM technology, binder jetting is particularly suitable for manufacturing small components in large quantities. In addition, the sintering process makes it possible to process materials that cannot be processed using melting or welding-based methods.

Extrusion of Fiber Reinforced Polymers

Liquid Deposition Modeling

High-Pressure Cold Gas Spraying

We are continuing to develop the high-pressure cold gas spraying process in order to use it as an additive manufacturing technology, particularly for multi-material components. It enables high material build-up rates of up to 10 kg/h and can process various material combinations without intermetallic phase formation. The Fraunhofer IGCV's cold gas spraying system consists of a cold gas cell with two 6-axis robots and a rotary swivel table. A plasma Giken gun is used for material application. The system can currently process steels, copper alloys and high-performance steels. The cold spray production laboratory offers individual analyses and support in evaluating suitable applications. In the FASTMULT, Coldspraymult and ACCURACY projects, we are developing the basis for this further development.

Liquid Metal Printing

One of the latest developments at the Fraunhofer IGCV is the Liquid Metal Printing (LMP) process. The basic principles are being developed together with the company Grob in the AluWire LMP project.

The raw material for the LMP process is an aluminum wire. A melt is then produced in a small crucible and liquid droplets are deposited to create the component. The LMP process enables cost-effective and time-efficient processing of aluminum alloys compared to other additive manufacturing processes.

The future of additive manufacturing

Additive manufacturing is one of the vital growth areas within manufacturing. Leading market reports predict an average annual growth of about 20 percent for the next five years. Fraunhofer IGCV assumes that this industry growth of additive manufacturing will not only be observed in a specific industry sector. Rather, it can be assumed that the use of additive manufacturing processes will increase in all industry sectors. In 2022, two studies were published on the future of additive manufacturing (An Additive Manufacturing Breakthrough & The Futures of Metal Additive Manufacturing 2030), to which Fraunhofer IGCV contributed. 

Video of the 3D printing process:

Production of multi-material components in the ForNextGen project

Knowledge transfer and industry development

Additive manufacturing is more than just a research field for Fraunhofer IGCV – it is a passion and a matter close to our hearts. For this reason, in addition to project-based knowledge transfer, we also take responsibility for industry development by:

  • sharing our knowledge at the largest industry events in Germany and worldwide (e.g., Fraunhofer DDMC Conference in Berlin, AM Forum in Berlin, Munich Technology Conference in Munich, AMUG (Additive Manufacturing User Group) in Chicago, SFF in Texas, USA).
  • participating in the advisory board or scientific committee at numerous conferences (e.g., Rapid Tech in Erfurt, ICAM in Orlando/virtually, USA).
  • providing the chairperson of the ISO Committee 261 »Additive Manufacturing« since 2019.
  • providing a member of the Executive Committee of the ASTM F42 committee »Additive Manufacturing« since 2020.
  • actively participating in committees of the Association of German Engineers (VDI) since 2014 and providing the chairperson of the VDI FA 105.6 »Safety in the operation of additive manufacturing equipment« since 2016.
  • participating in the EuroAM Steering Group of the European Powder Metallurgy Association (EPMA) since 2019.
  • actively participating in committees of the German Institute for Standardization (DIN) since 2014.
  • participating in the editorial board of the Springer journal »Progress in Additive Manufacturing« since 2016.

Fraunhofer IGCV in the Fraunhofer Competence Field »Additive Manufacturing«

Additive manufacturing is not only a cross-sectional competence and lead-topic at Fraunhofer IGCV, it is also intensively researched at 20 other Fraunhofer institutes. These institutes have joined forces in the Fraunhofer Competence Field »Additive Manufacturing«, in which institute representatives exchange information on research results within the Fraunhofer-Gesellschaft and further research needs. Fraunhofer IGCV is actively involved in this thematic alliance and thus contributes to the progress of the Fraunhofer-Gesellschaft in the field of additive manufacturing.

Plants - Metal Systems

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EOS M290

EOS M290
© Image courtesy of EOS
EOS M290

Technical Data:

  • Laser power: 400 W
  • Focus diameter: 100 µm
  • Installation space: 250 mm x 250 mm x 325 mm          
  • Layer thickness: from 20 µm
  • Mainly processed materials: 1.2709, 1.4404, 1.7131

Manufacturer: EOS Electro Optical Systems GmbH

AMLab location: Augsburg, Germany

The EOS M 290 is currently used primarily for processing various steels, e.g. case-hardening steels, tool steels and stainless steels. This is where the performance of the 400 watt fiber laser comes into play, which enables the economical production of a wide variety of components in a construction volume of 250 x 250 x 325 mm3.

SLM Solutions 125 HL

SLM Solutions 125 HL
SLM Solutions 125 HL

Technical Data:

  • Laser power: 400 W
  • Focus diameter: 70–100 µm
  • Installation space: 125 mm x 125 mm x 125 mm
  • Layer thicknesses: 20–75 µm
  • Production speed: up tp 25 cm³/h

 

Manufacturer: SLM Solutions GmbH

AMLab location: Augsburg, Germany

The SLM 125 laser beam melting system is currently used primarily for processing aluminum alloys such as AlSi10Mg. The available installation space reduction to (50 x 50 x 50 mm3) enables efficient examination of customer-specific materials. A high build-up rate can be achieved by coating in two directions.

SLM Solutions 250 HL

SLM Solutions 250 HL
SLM Solutions 250 HL

Technical Data:

  • Power: 400 W
  • Laser focus: 150 µm
  • Installation space: 250 mm x 250 mm x 350 mm          
  • Materials: Ti6Al4V, AlSi12
  • Layer thicknesses: 20 - 80 µm
  • Build-up rate: 2 - 10 cm³/h

Manufacturer: SLM Solutions GmbH

AMLab location: Augsburg, Germany

The SLM 250 HL from the manufacturer SLM Solutions GmbH is a system modified by the Fraunhofer IGCV for multi-material processing. Thanks to the software and hardware modifications made, metallic multi-material components can be generated with a high degree of automation. The reduction in installation space enables the economical construction of test specimens in small quantities. The system is equipped with a suction and vibrating sieve station for improved powder handling.

GMP300

GMP300
© Fraunhofer IGCV
GMP300
Technical Data:
  • 3D production by melting droplets
  • Installation space: 300 x 300 x 300 mm3
  • Materials (wire form): EN AW-4047, EN AW-4046, EN AW-7075
  • Droplet sizes between 450-750 µm
  • Layer thickness around 250-450 µm
  • Production speed max. 400 cm3/h

 

Manufacturer: GROB Werke Mindelheim

Location: Augsburg, Germany

Production System P-1

DM P1
© ExOne GmbH
DM P1

Technical Data:

  • Binder jetting modules: 2 piezoelectric print heads (4096 nozzles)
  • Usable build volume: 200 x 100 x 40 mm³
  • Resolution: 1200 dpi
  • Layer thickness: 30 – 200 µm
  • Production speed: 1350 cm³/h (at 65 µm layer thickness)
  • Mainly processed materials 17-4PH
  • Special features: Inert gas capable (nitrogen)

Manufacturer: Desktop Metal

Location: Augsburg, Germany

AconityONE

Technical Data:

  • Laser power: 4× Laser  750 W each
  • Laser focus diameter: 90 – 500 µm
  • Installation space size: Ø400 × 400 mm³
  • Minimum layer thickness: 10 µm
  • Substrate preheating: up to 500 °C

Manufacturer: Aconity3D GmbH

AM-Lab location: Augsburg, Germany

Sand Processing Systems

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Voxeljet VX500 (3D Printing System)

Voxeljet VX500
© Frederik von Saldern
Voxeljet VX500

Technical Data:

  • Multijet print head
  • Installation space: 500 mm x 400 mm x 300 mm
  • Layer thickness: 150 µm
  • Build rate: 21 mm/h (= 4.24 l/h)

Manufacturer: voxeljet AG

AMLab location: Garching, Germany

The VX500 3D printing system from voxeljet produces individual molds and cores quickly and economically, whereby detailed plastic models with PMMA and high surface quality are possible. Plastic or sand can be used as the particle material.

Voxeljet Test Axis / 3D Print Demonstrator

Voxeljet Testachse 3-D-Druckdemonstrator
Voxeljet Testachse 3-D-Druckdemonstrator

Technical Data:

  • Laser power: 30 W
  • Processable materials: Polyamide, Polystyrene
  • Installation space size: 200 mm x 250 mm x 330 mm
  • Layer thickness used: 0,1 mm
  • Typical processing time: 24 hours

Manufacturer: EOS Electro Optical Systems GmbH

AMLab location: Garching, Germany

The compact FORMIGA P 100 laser-sintering system enables the manufacture of plastic products made of polyamide and polystyrene. Small series and individualized products with complex geometries can be produced economically in an installation space of 200 mm x 250 mm x 330 mm.

Reference Projects Additive Manufacturing

Here you will find a selection of Fraunhofer IGCV reference projects on additive manufacturing. More projects on other topics can be found here.

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Further competences and lead topics at Fraunhofer IGCV

 

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Engineering and
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Multi-material
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Multi-material solutions
 

Composite technology

Intelligent lightweight construction and automated manufacturing processes

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Composite technology
 

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With numerous research projects along the entire recycling chain, we are ensuring a more sustainable approach to this group of materials. 

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Biological Transformation
 

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Casting technology

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Casting technology
 

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Artificial Intelligence (AI)

Smarter production – with artificial intelligence

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