Forum Software, Processes, Design I


Location: CongressCenter, 2nd floor, room Christian Reichart

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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.

Session 1

With additive mindset to a successful business case The added value of additive manufacturing is only an added value if it costs less or performs better in the end.

For this purpose, various application recommendations are given and practical examples are shown.
Dr. Sonja Rasch | Materialise GmbH
14:00 - 14:30

One possibility to enlarge the economic application possibilities of Additive Manufacturing is the combination of conventional and additive manufacturing techniques. In this constellation, Additive Manufacturing is only applied to produce functional and complex geometries while the basic body is produced by conventional manufacturing methods. From the combination of manufacturing processes, the problem of identifying suitable or cost-effective part divisions between the basic body and the functional or complex geometries can be derived. While relevant factors are the manufacturing costs of the selected manufacturing processes, the component volume, the material and their joining properties as well as the extent to which post-processing is necessary, the main task lies in the identification of indicators for the differentiation between the complexity of the functions which the base body and the functional elements have to fulfil. The aim is to manufacture parts at optimum costs using the respective advantages of each manufacturing technology.

The possibility of using software to select and evaluate the suitability of components for hybrid production as a combination of conventional and additive manufacturing processes is examined and presented. In this context, criteria for the selection of components are presented and tested, which can be used to evaluate the suitability of a part for Additive Manufacturing. The model is qualitatively validated by an exemplary application to a library of 3D-models of components using the 3D Partfinder. Subsequently the applicability of the software is critically discussed. The software enables an automated selection of parts from a database of 3D-models and can thus make a significant contribution to support users. Especially when dealing with large amounts of data, the complexity and time required for component evaluation increases. By applying the presented filters for the part selection, the software can automatically perform the necessary part comparison. It can be concluded that the complexity index allows a typologization of parts while economic parameters have to be respected as well. Especially products with a high number of variants but only small geometric deviations in volume and surface area offer the possibility of hybrid production. Advantages arise from a reduction of the complexity of the basic body in comparison to the former part and from the combination of several parts. It may be possible to produce a component that is manufactured in a small series by combining a basic body manufactured in a large series with additive manufacturing.

Dr. Kaj Führer | & TU München



14:30 - 15:00

Over millions of years of evolution, nature has produced optimal constructions. The transfer of this development logic into technology is a great challenge, since nature allows its products to grow on the basis of a set of rules stored in DNA, rather than defining them in a final design.

Dr. Moritz Maier (ELISE)

15:00 - 15:30
15:30 - 16:00

New improvement opportunities through applying topology optimization combined with 3D printing to the construction of gearbox housings

Dr. Pablo Barreiro und Michael Dinkel | SEW-Eurodrive GmbH & Co KG

Dr. Pablo Barreiro

16:00 - 16:30

Possibilities of additive manufacturing in switch cabinet construction under consideration of know-how protection aspects

Marvin Krecht (Weidmüller) und Andreas Hoppe (SLM) | Weidmüller Interface GmbH & Co. KG / SLM
16:30 - 17:00

AM integrated Direct Part Markings to link to individual digital part reports

Dr.-Ing. Ulrich Jahnke | Additive Marking GmbH