Metal-based additive manufacturing

Additive manufacturing: Laser-based powder bed fusion

The materials used must be available in fine powder form to apply a thin layer to the build platform. A powerful laser then selectively melts the powder (laser-based powder bed fusion, LPBF). The locations at which the powder is exposed can be determined directly from the CAD data of the component to be produced. This makes it possible to realize the most complex structures without tools, achieving maximum stability with low weight. Besides, a new form of functional integration is possible. For example, cavities can be left free during the building process to integrate sensor technology into solid material components. In this way, information can be collected in components at points otherwise difficult or impossible to reach.

Functional integration through multi-material solutions

Another research area for function integration is multi-material processing, where at least two different materials are used. These can then have any distribution both in the build direction and in the build plane. A possible application would be, for example, a carbide tool with integrated cooling channels made of copper. This technique can also be used to contact the integrated sensor technology. The development of multi-material solutions is a core competence of Fraunhofer IGCV.

Additive manufacturing in industry

To make the process even more economical in general, constant optimization occurs concerning in-, pre-, and post-process. Therefore, innovative improvements are constantly being implemented concerning the preparation of CAD and construction job data, the setup and preparation of the laser-based powder bed fusion systems, the post-processing of the components, and ideal powder recycling. Fraunhofer IGCV is focusing on these and other research areas at the cutting edge of technology to continue to increase quality and efficiency, reduce costs, and further advance the rapid progress of additive manufacturing in the industry.