Forum Fraunhofer Competence Field Additive Manufacturing

TUESDAY, 22 June 2021

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09:00 - 09:05

Welcome from the Rapid.Tech 3D Live-TV-Studio

Michael Kynast, Michael Eichmann und Prof. Gerd Witt | Messe Erfurt GmbH, Stratasys GmbH, Universität Duisburg-Essen

Michael Kynast, CEO Messe Erfurt GmbH
Michael Eichmann, Stratasys GmbH, Advisory Board Rapid.Tech 3D
Prof. Gerd Witt, Universität Duisburg-Essen, Lehrstuhl Fertigungstechnik, Advisory Board Rapid.Tech 3D

09:05 - 09:15

Welcome from the Rapid.Tech 3D Live-TV-Studio

Wolfgang Tiefensee | Thüringer Minister für Wirtschaft, Wissenschaft und Digitale Gesellschaft
09:15 - 09:45
  • Presentation of the current status of Additive Manufacturing at Daimler Buses
  • Presentation of our 3D printing parts which have already been installed in our premium buses
  • Change of the current supply chain due to the 3D printing technology
  • AM Big Picture - Daimler Buses
Ralf Anderhofstadt and Janis Kretz | Daimler Truck AG / EvoBus GmbH - Daimler Buses

Ralf Anderhofstadt and Janis Kretz

09:45 - 09:50
Greetings from the Rapid.Tech 3D Live-TV-Studio
09:50 - 10:00
Break & Chat Roulette
10:00 - 10:30

The sustainable design of structural components has to balance different criteria for part function, production and the overall life cycle. For SLM the interdependence of part geometry with the optimal build orientation and resulting need for support structures are especially critical to ressources and waste during production. A topology optimization based approach is presented to come up with more sustainable solutions for part geometry and build orientation.

Klaus Hoschke | Fraunhofer-Institut für Kurzzeitdynamik, Ernst-Mach-Institut, EMI

Klaus Hoschke 

10:30 - 11:00

Modern additive manufacturing methods allow extreme complexity in regards to the geometry of the built components. Due to the process's costs and performance, the binder jetting process makes it suitable to extend these capabilities to the lot sizes of series components. The combination with conventional methods is economically attractive, and the produced parts can easily be qualified. Larger series are at the moment quite rare due to a large proportion of manual work after printing. This article shows the reasons for these efforts and presents a process method that can significantly reduce manual labor. If the parts are processed in the suggested way, full automation in order to clean the components can be reached without additional engineering. The introduction of examples will demonstrate how this method can be adapted to several production scenarios.

Dr. Daniel Günther | Fraunhofer-Institut für Gießerei-, Composite- und Verarbeitungstechnik IGCV



11:00 - 11:30

Additively manufactured and subsequently functionalised ceramic components form the basis for various technical processes that can be accelerated significantly by combining heating and cooling systems in one component.
Compared to previous technologies used to produce actively cooled substrates, additive manufacturing technologies offer significantly greater geometric degrees of freedom when integrating the cooling system structures into a ceramic monolith. On the one hand, this means that the fluidic structures and connections can be directly realised in a volume-integrated manner.  On the other hand, it is possible to design the outer geometry in such a way that subsequent functionalisation is possible using highly productive and industrially introduced manufacturing technologies, such as screen printing of thick-film pastes.

In the presentation, the potential of the process combination of additive manufacturing of ceramic substrates (CerAMfacturing) and the subsequent functionalisation of these will be presented using one example each from medical and process engineering.

Uwe Scheithauer | Fraunhofer-Institut für Keramische Technologien und Systeme IKTS

- Born in 1980 in Dresden, Germany
- study of mechanical engineering at TU Dresden
- since 2005 scientific researcher at Fraunhofer IKTS in Dresden
- since 2013 responsible for three different suspension-based AM technologies for ceramic and
metal-ceramic components
- since 2018 responsible for AM strategy of Fraunhofer IKTS Dresden
- since 2021 Team Leader Additive Manufacturing

11:30 - 12:00

For a long time, the additive manufacturing (AM) of copper was a challenge. Due to the high thermal conductivity and reflectance in the infrared region, laser based AM techniques, like Laser Powder Bed Fusion (LPBF), were unable to efficiently process pure copper material. The absorption is increased significantly by using a green laser source. In addition, Binder Jetting recently showed remarkable progress in using copper with densities of over 95 %.
Copper is probably the most utilized material for efficient energy transfer. In combination with the advantages AM is known for, this will lead to improved and new applications in the future.   

Lukas Stepien | Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS

Lukas Stepien, holds a diploma in surface and nanotechnology from the University of Applied Science Südwestfalen and a master degree in polymer science from the Technical University Dortmund.
He is with Fraunhofer since 2012 working in the field of material development for printed electronics. Since 2016 he is the manager of the group Printing and since 2020 the group manager of Powderbed Technologies and Printing at Fraunhofer IWS.
His current research interest are the material development of reactive materials, printed electronics, and materials for additive manufacturing, e.g. Binder Jetting, Laser Powder Bed Fusion and Fused Filament Fabrication.     

12:00 - 12:30

Components produced by laser beam melting in a powder bed (PBF-LB/M) are particularly interesting for applications that require high quality standards and are needed in small quantities. There are several strategies for quality assurance. The fastest and most cost-effective is the analysis of the acquired data during the manufacturing process. Therefore process monitoring systems are offered by machine manufacturers. In addition to the current possibilities and limitations of the systems for quality assurance, the state of science will be highlighted in particular.

Martin Jaretzki | Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU

Martin Jaretzki

12:30 - 13:00

The ecological consideration of additive manufacturing (AM) processes and the parts produced is currently experiencing increasing interest. Compared to conventional processes, the group of additive manufacturing processes offers the possibility of fabricating components in a way that conserves resources (e.g. by eliminating tools) and allows for load specific manufacturing (e.g. by optimizing topology). The currently most widely used additive process in industry is Laser Powder Bed Fusion (LPBF). For this reason, various models for evaluating the sustainability have been developed for LPBF in recent years, which illuminate the process, the process chain and the component application to different depths. These models are presented and further challenges that need to be explored in the field are identified.

Christian Weiß | Fraunhofer-Institut für Lasertechnik ILT

Christian Weiß

13:00 - 15:45
Forum "AM Wissenschaft"
15:45 - 16:00
Coffee break and Chat Roulette
16:00 - 16:45

Panel Discussion "AM and Sustainability"

Moderation: Bernhard Langefeld / Roland Berger

Volker Hammes, Managing Director at BASF New Business GmbH

Dr. Jakob Fischer, Teamleader Application and Process, Heraeus Additive Manufacturing GmbH

Stefan Ritt, Geschäftsführer, EMEA, SPEE3D GmbH

16:45 - 17:00
Farewell to the Rapid.Tech 3D Live-Studio & handover to the digital award ceremony of the 3DPC