Forum Automotive & Mobility I

TUESDAY, 5 May 2020

Location: CongressCenter, Room Carl Zeiss rechts

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08:30 - 09:30
09:30 - 09:45
Welcome Carl-Zeiss Saal
09:45 - 10:15


Keynote 1 - Ferrari
Davide Abate & Giovanni Bulgarelli | Ferrari
10:30 - 11:15

In recent years, the established area of application for additive-manufactured components made of metal and polymer materials has expanded from industries such as aerospace, which are characterized by individual or small series production, to industries such as automotive industry, which are characterized by large series production. The technology is increasingly being utilized in the field of sports and super sports cars in particular, with the result that profitable yearly unit numbers in the region of 5,000 are being achieved in automotive engineering. This is due, on the one hand, to clever design trimmed for cost optimization and the associated outstanding lightweight construction potential, but also to the increasing stabilization and optimization of production processes. Current developments provide an insight into the potential that can be exploited in the automotive sector.

This presentation will show, on the basis of examples and projects, how the challenges of technology can be tackled in order to achieve profitable series production in the automotive industry.

Prof. Dr.-Ing. Claus Emmelmann | Fraunhofer IAPT



11:15 - 12:00

How the rail industry benefits from Additive Manufacturing

André Bialoscek | Bombardier Transportation

After graduating his Master of Enginnering in mechanical engineering and renewable energy studies in Berlin, André Bialoscek has been working for Bombardier Transportation in various positions and functions since 2011.

Since 2018 he is Head of Vehicle Physical Integration as part of the New Vehicle Construction branch at Bombardier’s site in Hennigsdorf and the main tasks is delivering final products to clients. The responsibility includes cab-interior and exterior rail parts as well as electrical and piping integration to be able to provide the best possible final vehicle to customers.

Based on that and to speed up the production of rail parts, specifically customized parts he is working with Additive Manufacturing for new trains, service and obsolescence topics.

12:00 - 13:30
Break & Visit the trade fair
Session 1
13:30 - 14:00

Industrial AM drives Bus

Ralf Anderhofstadt, Janis Kretz | Evobus/Daimler Buses

Ralf Anderhofstadt

14:00 - 14:30

WING3D: Multi-target optimized rear wing system for active aerodynamics

Sebastian Flügel | EDAG Engineering GmbH



14:30 - 15:00

Ford has been using additively manufactured production and assembly tools for several years. Up to 50% of the respective costs are related to the creation of design data. In order to scale the applications of Additive Manufacturing (AM), Ford is partnering with the software company trinckle to automate the design process.

For Ford, trinckle developed an internal application for the efficient generation of labeling jigs - to create new jig designs within a few minutes. Within an intuitive user interface, the user simply uploads the model data of the car body and the badges to be placed. Then he adds some standard elements such as handles, magnet mounts for fixation, edge guides and text fields by mouse click. The underlying algorithms automatically generate the geometry of the tool - precisely fitting the contour of the car body.

Dr. Ole Bröker | Ford/trinckle



15:00 -15:30
Session 2
15:30 - 16:00

Key enabler for the application of metal 3D printing in automotive engineering



16:00 - 16:30

Selektives Lasersintern von Polypropylen für die Automobilindustrie

Philipp Amend | Proto Labs Germany



16:30 - 17:00

Laser Metal Deposition (LMD) is an often-used technology for high quality repairs, wear- and corrosion protection as well as modifications on existing parts. With build-up rates of up to 500 cm³/min this technology can be used for fast, near net shape build-ups for e.g. applying optimized structural reinforcements to increase functionality or resistance to high local stress loads. A new variant of the well know LMD process is the High-Speed Laser Cladding.
In contrast to conventional LMD using High-Speed Laser Cladding, a laser beam is melting powder particles, which are fed coaxially into the laser beam, before these particles hit the substrate. This allows for a very low dilution of additive into workpiece – typically < 10µm – and high feed rates between 100-500 m/min. Layers generated by this new process can be locally adjusted in thickness between 50-300 µm per layer.
For automotive industry High-Speed Laser Cladding is already being investigated for a broad range of applications. Two use cases are currently very promising for automotive application: wear resistant layers on small valves or enhancement of brake discs.
In the presentation we will show recent results for the afore mentioned use cases, using new system technology and process parameters.

Dr. Sabrina Vogt | TRUMPF Laser- und Systemtechnik GmbH

Sabrina Vogt studied mechanical engineering at the Technical University of Cottbus (BTU), with a focus on lightweight and virtual production. She wrote her thesis at Fraunhofer Institute for Laser Technology in Aachen in the field of Additive Manufacturing, laser metal deposition welding of a binary Fe-Al alloy. From 2014 to 2017, she was employed at Fraunhofer Institute for Laser Technology where she focuses on laser softening on high strength steels. In 2019 she received his doctorate in mechanical engineering from RWTH Aachen University. From 2017 to 2019, she was employed at BILSTEIN GmbH & Co. KG. Since 2019 she is working at TRUMPF Laser- und Systemtechnik GmbH as industry manager in the area of laser surface treatments.