Lightweight construction and functional integration through additive manufacturing
The aim of this research focus is to develop design and manufacturing strategies for the production of highly integrated lightweight structures using additive manufacturing processes. Assemblies that were previously manufactured sequentially using various conventional manufacturing technologies are to be additively consolidated. This allows the component functionality to be increased, the performance of the components to be improved and the process chain to be significantly shortened.
Hybrid manufacturing
The focus is on integrating different manufacturing processes into a single machine platform in order to achieve higher process performance. The combination of additive and subtractive (WAAM+milling), but also various additive processes (WAAM+PBF) at one workstation can increase accuracy, surface quality and material efficiency and reduce throughput times. The aim is to develop hybrid process chains that offer a high degree of flexibility and cost-effectiveness.
Additive manufacturing of multi-material systems
Research focuses on the additive manufacturing of components made from different materials, such as steel and copper, in order to realise multifunctional properties. Various additive processes, such as Wire Arc Additive Manufacturing (WAAM) and Laser Powder Bed Fusion of Metals (PBF-LB/M), are investigated individually and in combination. Particular attention is paid to the process-reliable, material bonding of different materials and the resulting performance increase of the components.
Functionalisation of additively manufactured components
The targeted local adaptation of mechanical, thermal and electrical properties through the use of functional materials is being investigated. To this end, additive manufacturing is being further developed by means of binder jetting processes using renewable raw materials. The binder systems are modified by the addition of solid and/or conductive nanoparticles and selectively applied to functionally relevant areas of the component to enable location-resolved functional optimisation.
Additive manufacturing of novel materials
An additional focus is on the processing of highly reflective and thermally conductive materials such as pure copper and aluminium. Due to the special physical properties of these materials, adapted machine technology and process parameters are being developed to ensure reliable and high-quality component production. Together with research partners, glass materials and corresponding technologies for additive manufacturing are also being developed.
