Additive Manufacturing of Multi-Material Components

This stator for a radial flux electric motor was manufactured by Fraunhofer IGCV and uses the advanced multi-material manufacturing technology that led to the innovative design. In collaboration with Leap71, the stator was optimized using computational engineering. This involved the use of algorithms that automatically generate the design of the motor based on technical requirements. This methodology enables rapid design iterations and adaptation to specific production processes, allowing motors to be made even more efficient and application-specific in the future. This component represents an important step in the further development of electric motors and opens up new possibilities for future motor geometries and applications. Through the use of additive multi-material manufacturing, a new level of design freedom has been achieved, allowing more efficient, customized motors to be developed. Fraunhofer IGCV is also working on the integration of other materials such as ceramics and the incorporation of integrated sensors in order to further increase the functionality of the components.

Efficient propulsion systems for rockets have been under development since the 1960s. Thanks to its unique geometry, the aerospike engine offers the potential to increase performance by up to 20 % compared to the current generation of engines. However, due to technical challenges that could not be overcome with conventional design and manufacturing methods, the concept could not be implemented for use in launch vehicles. In particular, the problem of overheating in the spike could not be solved until now. Thanks to the new possibilities of additive multi-material manufacturing, new approaches are now available:

An aerospike engine developed by LEAP71 with the help of computational engineering was manufactured by Fraunhofer IGCV from two different materials using powder bed-based laser beam melting.
In cooperation with Nikon SLM Solutions AG, the Fraunhofer IGCV has developed a dual-metal deposition mechanism for the SLM Solutions SLM 280 HL system, which enables the production of large-volume multi-material components. This enables targeted material distribution in each voxel of the component, functional integration and a complex design to be implemented simultaneously.

Areas of the entire engine that are exposed to high temperatures are made of copper, which provides additional heat-conducting connections to less overheated areas. Segments of the aerospike with high structural loads, on the other hand, are made of high-strength steel. The aerospike engine is fully integrated. Copper fins on the outside serve both as cooling elements and as structural elements. This design philosophy gives the engine a more organic appearance than conventional rocket engines.

Fidentis is revolutionizing dental care by democratizing access to high-quality, yet traditionally expensive dental telescopes. Their innovative, patent-pending multi-material additive manufacturing technology enables the simultaneous processing of two or more alloys using a customized laser powder bed fusion machine (PBF-LB/M).

The production process consists of five key steps, aiming to create friction fittings made of cobalt chrome and gold that are individually tailored and affordable for everyone.
To find out more check the Webpage: FIDENTIS | Automated production of top quality dentures

Fraunhofer IGCV has developed a three-material processing technique using powder bed fusion (PBF), enabling the production of battery cell housings from aluminum, copper, and ceramic in a single manufacturing step. This approach allows for the creation of geometrically complex housings, offering significant flexibility in both design and production. By integrating multiple materials into a single process, the technique simplifies the manufacturing chain by eliminating the need for conventional methods like molding and stamping. This streamlining enhances production efficiency and reduces assembly requirements. Particularly suitable for small-batch production, the method supports rapid design adjustments during early development stages without incurring the costs of new tooling. Such flexibility is essential in the fast-paced development of next-generation battery cells, where quick prototyping and frequent design modifications are crucial. By

reducing iteration cycles and lead times, this process facilitates faster transitions from design to market, accelerating the introduction of new battery technologies. A key feature of the technique is its ability to incorporate ceramics as electrical insulation alongside conductive metals in a single powder bed fusion process. High ceramic density is achieved without extensive preheating, ensuring the structural integrity of the final product. Although the process involves longer build times and requires postprocessing through milling, the advantages of design flexibility and supply chain agility present a strong alternative to traditional manufacturing methods. In addition to multi-material battery cell lids, there is significant potential for additive manufacturing of the cell can, too. This component can also be produced using PBF.

However, maintaining high geometric accuracy is a current challenge, which can be addressed through specific distortion-minimizing measures. To improve the surface roughness of the manufactured cell can, the Fraunhofer IGCV has introduced a postprocessing step involving vibratory finishing. This ensures that the required surface quality is achieved, meeting the standards for battery cell applications.

Additive manufacturing (AM), such as laser-based powder bed fusion (PBF-LB/M), is gaining attention in the nuclear fusion industry. The flexibility of layer-based manufacturing allows highly stressed components like divertors, limiters, or target elements to be tailored for extreme material demands and enhanced functionality.

Laser Powder Bed Fusion of Tungsten Lattice Structures

Pure tungsten is preferred for plasma-facing components in future thermonuclear fusion devices due to its excellent plasma interaction properties. For dense, crack-free manufacturing of intricate, optimized lattice structures via PBF-LB/M, approaches like high-temperature pre-heating of the substrate to 800 °C are being developed to reduce tungsten's susceptibility to cracking by lowering cooling rates after melting.

Tailored W-Cu Composite Structures Using AM

In DEMO, sacrificial limiters are required to manage thermal shock loads during plasma instabilities and protect reactors from GJ-scale energy depositions. For this, thin-walled tungsten lattice structures produced via AM can serve as open porous preforms for liquid copper infiltration, enabling W-Cu composites with tailored material distribution—a promising solution for highly stressed plasma-facing components.

Additively Manufactured Target Elements for Wendelstein-7X

In order to dissipate the plasma energy, target elements with CW106C heat sinks below the plasma facing surface are installed. In the Wendelstein-7X (advanced experimental nuclear fusion reactor operated by the Max Planck Institute for Plasma Physics) stellarator, these modules consist of a large number of individual parts. By using PBF-LB/M, all part functions can be advantageously combined into one component and one manufacturing process, which not only significantly reduces the complexity of assembly and testing, but also enables customized cooling