The central idea of using material efficiently is already inherent to AM-technologies. The Hermle MPA additive manufacturing process aims to implement this sustainability approach even stronger within single components. Via a combination of various materials, a local and purposeful adjustment of properties is possible. So-called graded materials allow the combination of contrary properties like the high conductivity of copper and the high hardness of a tool steel.
MAP, a dynamic gas spraying process, is able to build up material without a molten phase. Inside a de Laval nozzle, powder particles accelerated via an expansion of a compressed and heated gas to a degree, where the kinetic energy is sufficient to create a metallurgical bond at particle impact. Through the utilization of multiple feeders, a mixture of powders with gradually variation in composition over building height is processed. The combination of this material build up with a Hermle C40 CNC milling machine allows a conventional post-processing directly inside the MPA-machine.
Within this lecture a short process description of the MPA-technology alongside with a few examples of a successful application within toolmaking is given. Subsequently the status of generating graded materials using MPA is discussed alongside with first results and ongoing challenges.