Our top-class 2023 congress program

What is it about?

The chemical and pharmaceutical industries of the future will be composed of a series of intensified processes where sustainability and energy consumption are optimized. Shape customization is perhaps the most powerful technique for process intensification. The possibilities to tailor shapes of reactors and separation units to specific applications result in units with enhanced mass, momentum and/or energy transfer. In this context, 3D printing is the perfect manufacturing technique one it allows the production of units or internals with customized shapes that can unlock new operation modes. In this presentation, I will show examples of reaction and separation units where 3D printing can be a game-changer in chemical and pharmaceutical industries.

Speaker/s

Carlos Grande is Associate Professor in King Abdullah University of Science and Technology (KAUST) since September 2021. Before joining KAUST, he worked as Senior Scientist in SINTEF Industry (Norway) for 10 years. He has a PhD from Porto University in Portugal (2005) where he also worked for 5 years as a Research Assistant. He graduated as Chemical Engineer in South University in Argentina (1998).

He works with process intensification applied to separation and reaction processes with strong focus on digitalization of processes and novel manufacturing techniques like 3D printing.

He has over 115 publications in international journals (h-index = 47) and 7 patent applications. He was coordinator of 2 European projects implementing 3D printing in chemical reactors (PRINTCR3DIT) and pharmaceutical industries (NESSIE).

What is it about?

3D printing service providers spend a lot of time responding to requests for quotations, particularly with regards to printability analyses and cost calculations. This ties up sales staff and technology experts who could otherwise be generating revenue.

Large OEMs face the challenge of making 3D printing accessible to many of their tens of thousands of employees in order to realize the full potential of the technology in terms of cost, delivery times and CO2 savings.

In this talk, I will use examples from the railway industry featuring giants and dwarfs to demonstrate how automation through software can help to answer daily questions from customers and employees regarding printability, manufacturing costs, and the selection of the most suitable manufacturing technology and material, resulting in validated savings of millions.

Speaker/s

Ruben Meuth is one of the founders and CEO of 3D Spark. Previously, he was Head of Business Development at the Fraunhofer Institute for Additive Production Technologies (IAPT). At the same time, in addition to various automotive industry projects (including Fiat-Chrysler / Maserati, Lamborghini, Dana), he led the "3D Supply" research project to explore part screening software approaches, especially for the railway industry. Further professional stations were Olympus Surgical Technologies, Audi and Airbus. His academic background includes a master's degree in industrial engineering with a focus on manufacturing technology, with a thesis at Laserzentrum Nord on the topic of "Part-Screening Software for 3D Printing".

What is it about?

Cavity Vat Photopolymerisation (CVPP) describes a process of producing a solid object filled with liquid resin during additive manufacturing (AM). Afterwards, the object gets cured in a second step, which connects the liquid and solid material phases. This allows to create composite multi-material (MM) products with elastomer and thermoset properties from one starting material. Dual-curing systems from technologies like Digital Light Synthesis (DLS) with thermal curing process steps are ideal for this purpose. MM-DLS using CVPP faces common MM-AM drawbacks and enables composite parts with customizable properties and additional advantages. To determine the potential for usage in end products, different variations of both combined material states are investigated mechanically in the form of test specimens. Results show, how mechanical properties are affected by changing the ratio of elastomer to thermoplastic content. Tensile tests proof that the interface between the two material states is not the weakest point of the multi-material resin parts due to chemical bonding. Small amounts of elastomer state inside the specimens changes the mechanical properties and improves the impact behavior significantly compared to the solid thermoset. By changing the ratio between thermoset and elastomer, the material behavior can be individually adjusted from a tough polymer to an elastomer.
 

Speaker/s

Education

09/2018 – today     University of Duisburg-Essen: Chair of Production Engineering, Duisburg
PhD Student (Dr. -Ing.): Automation for process chains of polymer-based AM 

10/2015 – 09/2018         Friedrich-Alexander-University, Erlangen-Nuremberg
Master of Science (M.Sc.): Mechanical Engineering

05/2017 – 08/2017        Shanghai Jiao Tong University, Shanghai, China
Semester abroad 

10/2016 – 03/2017    University of Wisconsin: Polymer Engineering Center, Madison, Wisconsin, USA
Visiting Scientist

04/2011 – 10/2015        Friedrich-Alexander-University, Erlangen-Nuremberg
Bachelor of Science (B.Sc.): International Production Engineering and Management            

Practical Experience

04/2021 – today        Production Project Manager - Additive Manufacturing Metal and Non-Metal
BMW Group, Additive Manufacturing Campus, Munich
-    Production process strategy
-    Lean management 
-    Sustainability 

10/2018 – 04/2021        Industrial PhD Student 
University of Duisburg-Essen, Chair of Production Engineering;
& BMW Group Promotion Programme
-    Process automation strategies
-    Process simulation

01/2018 – 09/2018        Masters’ student
BMW Group, Additive Manufacturing Center, Predevelopment, Munich 
-    DLS Technology
 

What is it about?

The laser-based additive manufacturing of metal components is one of the research focuses at Laserinstitut Hochschule Mittweida (LHM). A special feature at LHM is the further development of the selective laser melting technology (SLM) in the micro as well as in the macro range. On the one hand, precision parts with structural resolutions up to 30 μm and layer thicknesses up to 5 μm can be manufactured using Micro-SLM. Compared to the common SLM process, this means an improvement in the resolution by a factor of 4 - 5 and thus opens up completely new fields of application. On the other hand, large-volume components with low resolution requirements can be manufactured faster and more cost-effectively with the Macro-SLM. Laser powers in the multi kW range (single beam) are used for the process, whereby extremely high build rates (factor 30 compared to conventional SLM) are achieved. Furthermore, the building volume is currently being expanded to a size of 2 x 2 x 1 m³ in order to enable the production of large-volume components. The technique allows the manufacturing of complex geometries with structure resolutions greater than 1 mm and layer thicknesses greater than 0.5 mm.

Speaker/s

What ist about?

With the help of additive manufacturing, prototypes, spare parts or small series can be produced faster and more economically. New printing methods and materials are making this technology ever more versatile. 3D printing is now on the verge of a new boom: as an essential element in making production and the supply chain climate-neutral. Chemical companies should use these advantages in their own company and also examine what economic prospects could be associated with the development of new materials or even business models.

Speaker/s

BRIEF RESUME

Götz Erhardt is a Senior Managing Director leading Accenture’s integrated digital engineering and manufacturing consulting practices and services in Europe. He has over 25 years of consulting experience with multinational clients in the energy, chemical, and industrial markets. Götz specializes in corporate strategies, enterprise transformation and strategic change. Götz and the Industry X teams currently support our clients on topics such as the energy transition and circular economy, industrial competitive strategies, and digital transformation of engineering and manufacturing. He leads projects and client case work across Europe where Götz works with Senior Management of multinational industrial companies.

He has led multiple client engagements for companies such as Siemens, E.ON, BASF, DuPont, Shell, LANXESS, thyssenkrupp and BAYER in the area of Enterprise Transformation over the past 15 years.

Götz also serves as a member of the Board of the Accenture Foundation in Germany which provides pro bono services to disadvantaged stakeholder groups to equip them with skills to succeed in the digital age.  

EDUCATION

M.A. Philosophy Free University Berlin, Germany
MBA University of Bradford, UK

What is it about?

AddiMap is the first open, privacy-compliant and secure B2B platform
ecosystem for additive manufacturing. The focus is on metallic materials, which
are processed with the PBF-LB process. The platform consists of a marketplace
for process parameters with the associated starting materials as well as the
resulting material data. The bulletin board gives users the opportunity to initiate
joint development projects for new materials and process parameters. The goal
is to drive the industrialization and market growth of additive manufacturing
technology for more sustainable production processes. The data sets are to be
used to offer so-called smart services by means of artificial intelligence and to
enable material and process innovations.

Speaker/s

Experience
2017 - today Managing Director NuCOS GmbH, Stuttgart, Germany
2013 - 2016 Development Engineer, MBTech, Stuttgart, Germany
2009 -2012 Independent activity as project engineer – simulation,
Modelling and analysis
Training
2002 - 2009 Dipl.- Ing. Automation Technology in Production, University
Stuttgart Germany

What is it about?

The mechanical properties of components in laser-based powder bed fusion of plastics depend on the formation of a melt pool with a homogenous surface and temperature. The transient temperature of the melt pool has a decisive influence on the melting of particles and the cooldown behavior defines the pore formation. Within the scope of this work, the influence of the component geometry and the resulting scan vector length on the pore volume distribution and sphericity is investigated. Infrared thermography process monitoring and X-ray micro computed tomography show that the sample geometry is the main influence on the size, and shape of pores. At reduced distances to the center of mass, the melt pool temperature is at elevated levels for extended periods. This coincides with a reduced number and increased sphericity of pores.

Speaker/s

Education
11/2020 - present
Doctoral program at the Technical University of Munich (TUM),
Graduate Centre of the TUM School of Engineering and Design
Subject: Quality assurance in laser-based powder bed fusion of plastics
10/2014 - 02/2020
Studies at the Friedrich-Alexander University Erlangen-Nuremberg (FAU)
Subject: Mechanical Engineering (Production Engineering), M.Sc.
10/2013 - 01/2018
Studies at the Deggendorf Institute of Technology (DIT)
Subject: Mechanical Engineering (Engineering and Design), B.Eng.
07/2013
Advanced technical college entrance qualification (equivalent to A-levels)

Professional Experience
04/2020 - present
Research associate at the Technical University of Munich, TUM School of Engineering and Design, Professorship of Laser-based Additive Manufacturing
06/2018 - 02/2020
Student assistant at the Friedrich-Alexander University Erlangen-Nuremberg, Faculty of Engineering, Institute of Polymer Technology
03/2017 - 12/2017
Internship at 3D|CORE GmbH & Co. KG, Herford, Germany
03/2016 - 09/2016
Internship at AUDI AG, Neckarsulm, Germany
09/2014 - 02/2016
Tutor at Deggendorf Institute of Technology,
Faculty of Mechanical Engineering and Mechatronics

What is it about?

3D printing thought bigger
3D printing opens up entirely new product and manufacturing approaches. However, many 3D printing processes are too expensive and too slow for industrialization. The key here is to produce large quantities in a short time. This is even more true for the additive manufacturing of large-volume and resilient plastic components.
The production of plastic components from injection molding granulates is only environmentally friendly at first glance in terms of substituting energy-intensive manufactured components. When the materials to be processed and a closed-loop system are included in the production of the components, the SEAM (Screw Extrusion Additive Manufacturing) process can represent a quantum leap for environmental protection and sustainable application of 3D printing.

Speaker/s

What it is about?

BASF is the first company to offer multi-ton quantities of 3D printed Catalyst for commercial uses. This presentation will give an introduction to the challenges of 3D printing catalysts, including the nature of the catalyst materials (acidic, basic, heavy metals, etc) while explaining the importance of porosity and strength on performance. The presentation will outline the challenges in entering an existing plant as a drop-in solution and give an overview into the first commercial pilot unit which has been operational for more than 3.5 years.

Speaker/s

Marco Kennema finished his MSc at the University of Guelph Canada in 2014, he finished his PhD at the Max Planck Institute für Kohlenforschung in 2016. He has worked in BASF for 6 years across R&D and Digitalization.

What is it about?

toolcraft is a medium-sized company that specializes in the production of high-end precision parts and components. Since 2011, the company has been manufacturing 3D printed components, mapping the entire additive value chain in metal.
Software is one thing - manufacturing practice is another. For this reason, we use, cooperate and further develop with software partners in order to make faster progress together and drive forward industrialization in AM.
In our lecture we will give you insights into the digitization of the additive process chain, the maintenance process, the simplified and automated re-machining as well as the use of Virtual Reality Software, with which we can pass on our additive manufacturing knowledge in a practical and self-taught way in our AMbitious training courses.

Speaker/s

Joined the company since: 2002

2002 - 20011: Focus on machining
Since 2011: Focus on Additive Manufacturing (AM)
Since 2019: Focus of new business unit
Current position: Head of additive manufacturing

What is it about?

Laser based powder bed fusion of polymers (PBF-LP/P) is an industry disruptive process that allows the mass production of highly complex functional components. It is necessary to achieve certain fire properties for the availability of applications in fields such as electrical, electronic components, or aviation. Therefore, the goal of this work is to dry mix halogen-free flame retardants to modify the flame characteristics of the polyamide 6 components. For this purpose, the process-relevant powder properties with differing flame retardant contents were investigated first to subsequently produce test specimens for mechanical and flame retardant investigations. The flame retardant tests confirm that for the industrially relevant UL-94 test, a classification of V0 is achieved, and by investigating the fire behavior of polyamide 6 for the first time, it is possible to show that halogen-free flame retardants have the potential to expand the applications of PBF-LP/P.

Speaker/s

Simon Cholewa:

Master's degree in mechanical engineering with a focus on plastics and laser technology at the Friedrich-Alexander-University Erlangen-Nuremberg, Germany. Visiting scientist at the Polymer Engineering Center in Madison, Wisconsin with Tim Osswald in 2019. 
Since 2020 research assistant in the field of additive manufacturing at the Chair of Plastics Technology at the Friedrich-Alexander-University Erlangen-Nuremberg, Germany.

Speaker/s

What is it about?

Bosch Advanced Ceramics is a manufacturer of ceramic components used in different applications such as medical, industrial, or chemical. The focus is oxide ceramics which are advantageous in chemical industry due to their technical properties.

This presentation covers insights of the whole process chain that is needed to manufacture ceramic parts, challenges on the way to series production as well as a use case from the industry.

Speaker/s

Nikolai Sauer has been working on Additive Manufacturing of Ceramics since many years and is one of the early adopters bringing this technology into industrial viability and production. He first came in contact with this new technology during his university time and started in 2017 as a process engineer dedicated to AM in a newly created team dedicated to Ceramics at Bosch. As Head of Additive Manufacturing he brought AM to an even bigger scale and implemented additional key processes.

Today as CTO of Bosch Advanced Ceramics, he is focused on extending novel ceramic technologies to more and more applications.

What is it about?

Machine-integrated quality assurance is already a decisive success factor for the manufacturing industry. This trend is now increasingly entering the AM industry. ZEISS is addressing this trend with new in-process monitoring technology solutions, initially for the powder bed fusion based technology. The objective is to make the AM production process more stable, cost-efficient and flexible, and to make certain applications feasible in the first place. Initially, ZEISS offers solutions for the existing challenges in generating high-quality, reproducible digital QA data and fully automated data analysis using machine learning and algorithms for reliably determining defect types, characteristics, frequencies, etc., - without disrupting the production process. Furthermore, the challenge consisting of combining in-process monitoring data with CT data from special test objectes is addressed (ZEISS Parameter Development). This enables the entire production process to be significantly optimized.

Speaker/s

Dr. Bernhard Wiedemann:

In senior positions over 25 years of experience in the automotive, mechanical engineering, aerospace, measurement technology and consulting industries, among others in the field of Additive Manufacturing / Advanced Manufacturing, R&D, Strategy, Business Development, Transformation Processes.

Stations:
Since 2019 Carl Zeiss / Director Business Development AM
TMG Consultants
Daimler
Mercedes Benz Technology
Studies and doctoral studies / University of Stuttgart

What is it about?

The surface of PBF-LB/P parts is known for its rough texture and external appearance, whereby the surface roughness has a significant influence on the mechanical properties. Chemical smoothing with solvents is a well-known method for influencing the surface texture of PBF-LB/P component. Due to the further development and industrialization of the process, the post-processing method is becoming increasingly attractive for the use in the automotive industry. Chemical smoothing reduces the surface roughness and seals the surface, which leads to a change in the functional as well as optical properties. Due to the significant increase in elongation at break at a near constant tensile strength after smoothing, this post-processing method has the potential to expand the range of application for of PBF-LB/P parts in the automotive industry. This paper is investigating the influence of the chemical smoothing process on the mechanical properties and surface roughness of polyamide 12 (PA12) parts.

Speaker/s

PROFESSIONAL EXPERIENCE
Since 05/2021 BMW AG, Additive Manufacturing
Doctoral student
Chair of Hybrid Additive Manufacturing, Ruhr-Universität Bochum
- Investigations of surface quality and modification
Additively manufactured vehicle components
07/2020 – 02/2021 BMW AG, Additive Manufacturing
Masterand
05/2019 – 11/2019 University of Wisconsin-Madison, Polymer Engineering Center,
USA
Research Associate
09/2018 – 04/2019 BMW AG, Additive Manufacturing
Trainee
06/2017 – 02/2018 Blackwave GmbH
Working student

EDUCATION
03/2018 – 04/2021 Master of Science in Mechanical Engineering at the
Technical University of Munich
Thesis: “Correlation of Mechanical Properties with
Machine Sensor Data of the Multi Jet Fusion Additive
Manufacturing Process”, written at the chair
for Laser-based Additive Manufacturing
09/2014 – 03/2018 Bachelor of Science in Mechanical Engineering at the
Technical University of Munich
Thesis: “Concept development and construction of a
Module for coupling high-frequency vibrations
in the RTM process”, written at the Chair of
Carbon Composites
09/2004 – 06/2013 Abitur at the Landschulheim Steinmühle, Marburg

The field of 3D printed electronics faces several challenges. Traditional methods such as jetting or dispensing-based technologies with nanoparticle-based inks have limitations in terms of the range of available materials and their properties. These methods often result in materials that are difficult to work with due to their poor conductivity or mechanical properties. At Syenta, we are utilizing a promising alternative approach which involves a novel form of localized electrodeposition. This process consists of selectively depositing materials onto a surface using an electrode, with precise control over the deposition resulting in accurate and uniform results. Furthermore, this method allows for the printing of a wider range of materials with improved properties, including conductive metals and other difficult-to-print materials such as polymers and semiconductors. This innovation has the potential to revolutionize the field of 3D printed electronics, enabling the production of more advanced electronic components and devices. Thus, leading to a more efficient manufacturing process and sustainable future when compared to the conventional fabrication methods of today.

Speaker/s

What is it about?

Chromatic 3D Materials produces flexible, functional and economical components by means of the
patented reactive liquid deposition, RX-AM Reactive Liquid Additive Manufacturing.
The smooth, non-porous polyurethane elastomer can be used for components up to in vivo
Applications.
The biocompatibility and stability of the materials are explained and illustrated with measurements of the
Surface area and porosity were compared. The pressure and the adhesion to the most diverse
Substrates are presented to be able to produce hybrid components. There will be new
Possibilities of manufacturing complex components are presented, in which many
Steps compared to traditional manufacturing processes can be saved and can be
open up new geometries for the manufacturer.
As another suggestion in the field of multi-material printing is presented. Here you can
Prints with different material properties can be realized in the same component.
This is particularly interesting in applications where a contact surface should be as soft and as
should be elastic, but at the same time high stability must be ensured.

Speaker/s

Dr. Barthel Engendahl received their PhD in Engineering Chemistry at RWTH in 2009
Aachen. Since then he has employed both in industrial research laboratories
as well as in various start-ups with innovations in the field of chemical and
Plastics industry.
Mr. Engendahl holds several patents in the field of renewable polymer production,
Application of renewable chemicals in everyday life and 3D printing
of liquid systems.
He has been managing director of Chromatic 3D Materials GmbH for 3 years. He
deals with the application development of 3D printing for industrial
relevant components. He wants the knowledge he has learned about the successful application of the
Distribute 3D prints.

What is it about?

While 3D printing has moved from mainly prototyping to production over the last decade, we still use mostly the same design software and methods from the early 80s. CAD’s foundation is the BREP (boundary representation) that, when created, was ideal for digitizing drafting. CAD successfully replaced the drafting board for drawing, but what’s next? Rather than incrementally improving upon CAD, a totally new underlying model is needed, breaking boundaries between analysis and design, to handle the ever-increasing complexity of modern manufacturing. Implicit modeling + Field-Driven-Design is built for the future of product development and already today is enabling a wide range of products from more efficient turbine engines to zero-energy hydrogen-powered aircraft to lightweight, autonomous factory robots. Engineering is about breaking boundaries and exploring the art of what’s possible, and new software is the tool to enable us to deliver higher-performance products.

Speaker/s

Bradley Rothenberg is the CEO and founder of nTopology, an engineering design software company based in New York City. Since its founding in 2015, nTopology has served the aerospace, automotive, medical, and consumer products industries with advanced engineering software that enables users to design, test, and iterate faster on highly complex parts for production with additive manufacturing. Bradley has been developing computational design tools for additive manufacturing for more than 15 years. He actively works to advance the industry, often speaking at industry events around the world including Develop3DLive, Talk3D and formnext. He is often quoted in trade publications, interviewed on industry podcasts, and has been included in Forbes Magazine. He studied architecture at Pratt Institute in Brooklyn, New York

What is it about?

While additive manufacturing processes are already established in other industries, their application in the construction industry is still a marginal topic and is currently largely limited to extrusion printing.
This paper deals with additive manufacturing (AM) by selective cement activation (SCA) for concrete components and a possible application in construction practice. The focus of the study lies on the mechanical properties of the hardened concrete samples and the identification of significant parameters such as the loading direction or the size of the specimens. Compared to other publications, which mainly deal with small specimens on material scale, the experimental scope in the present study is extended to larger structural elements to ensure their transferability to practice. It is shown that the loading direction versus the orientation of the layers as well as the horizontal orientation of elongated structural elements in the particle bed have a significant influence on the properties of the additively manufactured samples. There is a need for future research to perform a comprehensive fundamental investigation on material properties in order to derive a material model that is resilient for design concepts through larger amounts of data.

Speaker/s

Professional experience
04/2022 –Today
University of Applied Sciences Munich, Munich, Research
Research assistant at the Faculty 02 – Civil Engineering in the area of 3D-
Pressure of concrete

03/2019 – 05/2021
Englhardt Grad Kassner, Munich, structural design
Project Engineer Building Construction (performance phases 02 to 05), focus on reinforced concrete and steel structures; assuming project management; 3D modelling, BIM planning (Revit) & parametric modelling (Rhino + Grasshopper); contribution to bridge competitions

03/2017 –02/2019
Bollinger + Grohmann, Munich, structural design
Project engineer for structural engineering, focus on reinforced concrete and steel structures; internal training for colleagues on parametric modelling in Rhino + Grasshopper; supervision of a student workshop „Fabrication intelligente“ (ENSAV – Tomas Saraceno)

03/2016 – 09/2016
sbp – schlaich bergermann partner, Stuttgart, structural design
Internship at sbp: Final thesis on the topic of tree structures & force density method; active participation in the project work (Stahlbrücken, LPh 02 – 05).

07/2015 –08/2015
setec tpi, Paris, France, structural design
Internship in the field of quotation calculation: preparation of an internal price-
Database in close contact with the responsible engineers.

04/2012 –08/2014
Mayr | Ludescher | Partner, Munich, structural design
Working student in the field of structural design of reinforced concrete, wood and metal structures. Creation of FE models, verification according to Eurocodes
Technical University of Munich, Munich, teaching

04/2014 –08/2014
Chair of Structural Mechanics,
Exam preparation seminar for construction mechanics for approx. 200 students

10/2010 –03/2012
Chair of Structural Mechanics,
Tutor for Bachelor students, follow-up of the lecture

10/2011 –03/2012
Chair of « Computation in Engineering »,
Tutor for Bachelor students

06/2009 – 09/2009
Gebrüder Huber Bau GmbH, Munich, construction company specializing in earthworks
Construction site internship: supervision of construction execution, measurement, etc.

Education
10/2013 – 09/2016
Ecole Nationale des Ponts et Chaussées (ENPC), Champs-sur-Marne, France, and
Technical University of Munich (TUM), Munich, Germany
Master of Science (TUM, average 1.5) and Ingénieur diplomaé de l’Ecole nationale des Ponts et Chaussées (average 16,1/20):
Binational double degree course in civil engineering with specialization in the field of statics, solid construction, metal construction, dynamics and timber construction
Master’s Thesis “Tree Supports and their Application for Pedestrian Bridges”, with very good marks

10/2009 – 09/2013
Technical University of Munich (TUM), Munich
Bachelor of Science in Civil Engineering, degree (average 1.7) among the top 6% of the last two comparative years
Bachelor Thesis “Comparative Consideration of Understressed Arched Structures on the Example of Atrium Roofs”, with very good marks

09/2000 – 07/2009
Pater-Rupert-Mayer Gymnasium, Munich
University entrance qualification (average 1.0), major: Mathematics and French

What is it about?

Supply chain resiliency and regionalizing production has received tremendous attention lately, and Additive Manufacturing (AM) has been elevated as a potential solution for many related issues. Yet, AM has historically been an enabler of only a small piece of that equation, primarily local production of prototypes and low volume products. To create a serious impact in reshoring will require not only a manufacturing process that can scale, but also addressing the triple threat of climate change, energy, and soaring costs.

Speaker/s

What is it about?

In this lecture, we will explore the latest advancements in design tools and automation techniques for medical additive manufacturing. We will discuss how new design software and automation processes are enhancing the precision and efficiency of medical device production, and how process development is enabling the creation of more complex and customised medical implants. The lecture will also examine the challenges that arise in adopting these new technologies, and how to overcome them to ensure successful implementation. Overall, attendees will gain valuable insights into the latest trends in medical additive manufacturing, and how to harness them to drive innovation in the field.

Speaker/s

I am passionate entrepreneur, technology executive, leader andstrategist. I am expert in additive manufacturing, medical 3DPrinting, AM technology implementations and applications. I have amechanical engineering background and completed a bioengineeringMSc program. I am co-founder of BTech Innovation, Trabtech, Earfit and AddParkcompanies who are working in the field of Additive manufacturing invarious vertical industries. I have ability to manage multi-disciplinary projects and to navigatecomplex challenges. Our companies developed/developing manyinnovative AM products and services. With our highly skilledengineering team, we are passionate to change industries withdisruptive technologies.

What is it about?

In today's world of rapid technological innovations, customers demand products and integrated solutions that are always up-to-date, complete with the latest designs and technologies. That shortens established product life-cycles and drives demand, not just for frequent product updates and incremental improvements but also for complete makeovers and breakthrough technology innovation. The shortened life cycle and the need for up-to-date as well as for personalized products leads to a significant additional (personnel) effort in the development of these products. One possibility to (partially) automate the personnel-intensive product development is the use of smart digital assistance systems. On the one hand, these are able to reduce the effort and, on the other hand, to detect or avoid potential errors at a very early stage of the development. The presentation will provide an insight into the possibilities, both technological and economic, of using smart digital assistance systems.

Speaker/s

Dr.-Ing. Stephan Ziegler is managing chief engineer at the Digital Additive Production at RWTH Aachen University. In addition, he is director for R&D with focus on systems engineering, process development and component design at the ACAM Aachen Center for Additive Manufacturing GmbH. He brings broad expertise in additive manufacturing, including materials, process chains, and approaches to digitization. He holds degrees in mechanical engineering, industrial engineering and business administration.

What is it about?

Esophageal cancer is statistically the eighth most common type of tumor in the
world. The 5-year mortality rate for esophageal cancer is over 80 %. This is
caused by the symptoms (difficulty swallowing, feeling of pressure), which usually
become apparent only at a late stage, and the lack of routine screening examinations.
For the palliative treatment of tumors that are usually no longer operable,
a metal mesh stent is currently being used to enable the patient to enjoy as high
a quality of life as possible by swallowing as unhindered as possible.
Due to its standardized geometry, this stent entails some disadvantages and
problems, which are to be eliminated by an additively manufactured, patient-specific
stent. This should not only significantly improve patient well-being, but also
lead to a much lower resource burden (financial and human) for the healthcare
system due to less frequent stent changes.
In this publication, different additive manufacturing options for direct or indirect
fabrication of individualized esophageal stents are listed and compared. In addition
to conventional additive manufacturing by material extrusion, additive manufacturing
on a rotating roller is also examined in more detail. Furthermore, indirect
methods or process chains such as centrifugal casting with additively manufactured
cavities and AM post-core technology are compared. Here, the respective
current research statuses with their advantages, risks and challenges are evaluated
and illuminated.
The paper concludes with a comparison of the concepts considered and an outlook
for their implementation in clinical applications.

Speaker/s

Promotion in mechanical engineering

11/2020 – today    

PhD at the Ruhr-Universität Bochum, Additive Manufacturing Plastics

PROFESSIONAL EXPERIENCE (sector specific)

06/2017 – today    

Impetus Plastics Engineering GmbH, Project Manager Development Engineer

 09/2015 – 05/2017

Impetus Plastics Engineering GmbH, working student and Master's student

03/2015 – 08/2015

BMW Group, Bachelorand

03/2014 – 07/2014

BMW Group, student in practical semester

STUDY

10/2015 – 05/2017

Rosenheim University of Applied Sciences

Applied research and development, focus

Plastics. Master of Science (M. Sc.), final grade 1,2.

10/2011 – 07/2015

Rosenheim University of Applied Sciences

Plastics Engineering, Bachelor of Engineering (B. Eng.), final grade 2.3.

The development and qualification of an additive process chain for the production of optically transparent, complex glass assemblies based on the “Laminated Object Manufacturing” (LOM) is a new and innovative manufacturing strategy. With the classic LOM, contours are cut out of sheet metal or ceramic green foil, stacked in layers one above the other and laminated, i. e. so tightly bonded that a component with the same material-technical properties is formed from each of the individual layers.
Due to the optical advantages of glass, the increasing complexity of the elements and assemblies to be manufactured, as well as the application requirements, conventional glass processing is reaching its limits in both cold and hot processing.
The qualification of individual process steps to the LOM process from the combination of laser beam cutting and diffusion welding forms the basis for manufacturing large-scale and complex glass components. In accordance with the requirements regarding the machining strategy and the edge qualities were evaluated and process parameters for diffusion welding were derived. This presents a challenge for the bonding of glass. Emphasis was placed on deriving technical target parameters in the cutting process that correspond to the requirements of diffusion welding.
In addition to the numerical simulation, application patterns were developed, manufactured in the laser cutting process and welded together. These were component applications with requirements for heat management or in the optical area. These were tested to demonstrate the performance of the process and to assess the limits of the manufacturing strategies.

Speaker/s

What is it about?

The predicament:
- Thoracic aortic dissection (diseases of the cardiovascular system): high mortality rate despite advancing diagnostic and therapeutic techniques, fatal complications, therapeutic measures are associated with high risk and burden for the patient due to their invasiveness
The alternative:
- Aortic Gen-i stent: development of patient-specific additively manufactured aortic stents based on numerical methods.
- Innovation/uniqueness: the aortic stent as an additively manufactured high-risk implant, which has durable properties after plastic deformation
Content/Topics:
- Aortic stents in different stages of development as well as post-treatment conditions, geometry, modified manufacturing.
- FEM simulation of a balloon-expandable aortic stent, load models for fatigue strength
- Improvement of surgical technique, reduction of invasiveness, consideration of head vessels, reduction of surgical time
- Surgical risk can potentially be reduced, costs for treatment and post-treatment of the patient can be drastically reduced
- Example of successfully used and functioning AM process for 3D-printed aortic stents.
- The project is carried out in collaboration with, among others: Prof. Dr. med. Christof Schmid (Director of Cardiac, Thoracic and Cardiovascular Surgery at the University Hospital Regensburg) and Prof. Dr.-Ing. Thomas Schratzenstaller (Head of Laboratory for Medical Devices OTH Regensburg).

Speaker/s

Matthias Kern is a Master of Applied Research in Engineering (M.Sc.) specializing in medical technology, quality management. Head of the medical technology division of FIT AG since 2018, he is responsible for the production of medical devices class I-III by means of additive manufacturing processes (EBM or PBF-EB/M, laser melting or PBF-LB/M, SLS or PBF-LB/P, PolyJet) and manages national and international customer projects as well as international R&D projects. His special competence is the customized volume manufacturing service ADM-CV.
 

What is it about?

Optimizing Lightweight and Sustainable Design with Digital Twins and automize you processes

In today's fast-paced world, businesses need to adapt quickly to changing market demands while keeping sustainability at the forefront. This is where efficient shaping of sustainable performance parts comes into play, using innovative technologies such as digital twins, automation and lightweight optimization. Topology optimization and generative design are key techniques that enable businesses to create simple yet effective solutions that meet their performance requirements while reducing weight and waste. With the help of these tools, you can speed up and optimize your design process and stay ahead of the competition while reducing the environmental impact.

This presentation will cover the following topics:

What possibility do you have to generate efficient designs?
How does performance and lightweight fit together?
How to leverage digital twins and automation to drive customized processes?
What impact it could have for your customers and business ?
How can the use of digital twins and lightweight optimization increase your business's operational efficiency?

Speaker/s

Sebastian Stahn

Professional experience

01/2023 - 04/2023 Ansys Germany GmbH
ACE Lead Application Engineer & Product Manager Structural Optimization
05/2020 - 12/2020 Ansys Germany GmbH
ACE Lead Application Engineer
08/2016 - 04/2020 Ansys Germany GmbH
ACE Lead Application Engineer - Mechanical
06/2008 - 07/2016 Ansys Germany GmbH
ACE Fluid Dynamics & Advanced Meshing
11/2005 - 05/2008 CFD Network GmbH
Consultant Fluid Dynamic

Education

2016 - 2019 Universidad Politécnical de Madrid
Master in Numerial simulation with Ansys
1999 - 2005 University of Kassel
Dipl. - Ing. Mechanical Engineering

Jiří Drozda

Principal Application Engineer for Ansys optiSLang & Additive

Responsible for projects in EMEA

Working for Ansys/Dynardo for more than 7 years

More than 15 years experience with simulations in ANSYS

Background:   Structural mechanical,  additive manufacturing, non-linear materials models and Robust Design Optimization

Speaker/s

What is it about?

Conventional cosmetic hand- and arm prosthetics are without any functions. They are made for the cosmetic restoration of the patient. If patients would like to add function to the prosthesis they have to accept a high decrease of the cosmetic outcome. Schubert and Braun have been closing the gap, while they developed passive movable hand- and arm prosthetics which are on the highest cosmetic level. It is possible because of integreated prosthetic hands, parts of the hand, wrist- and elbow joint, which are getting integreated into arm prosthetic devices. The products are produced by 3D-printing technology, after they are designed digital.

Speaker/s

Training:
01.08.1995 - 28.02.1999 Orthopaedie- und Rehatechnik Dresden College:
15.08.2000 - 31.12.2000 Milwaukee Area Technical College, USA

Master degree:
01.04.2008 – 28.02.2009 Bundesfachschule for P&O, Dortmund
Experiences in foreign countries
01.08.2000 31.07.2001 17th CBYX program, USA

Work Experience:
01.03.1999 - 31.07.2000 Orthopaedie- and Rehatechnik Dresden 01.01.2001 - 30.06.2001 Orthotic Prostetic Center, Milwaukee, USA 01.01.2001 - 30.06.2001 The Natural Technology, Milwaukee, USA 11.11.2001 - 31.08.2002 Bauerfeind Prothetik, VS-Schwenningen 01.09.2002 - 31.08.2004 Brillinger Orthopädie, Tübingen 01.10.2004 - 30.09.2005 EproTec, Berlin
01.02.2006 - 31.10.2009 Orthopaedie- and Rehatechnik Dresden
01.11.2009 - 31.08.2013 Hans Sachs OST, Dresden
06.09.2013 - today schubert + braun prothesenwerk, Dresden

What is it about?

This presentation delves into the challenges of scaling industrial 3D printing and how solving process complexity is key to unlocking its full potential. Making better physics-based decisions is crucial in overcoming these complexities. Drawing from extensive experience in the field and as the founder of Helio Additive, a deep-tech software company, David will provide valuable insights and practical solutions for attendees looking to drive the growth of their own 3D printing operations.

Speaker/s

David Hartmann is a seasoned leader with a wealth of experience in international business. With over 16 years in the chemicals industry, he previously he served as the Senior Vice President of Growth Ventures at Covestro, where he led a global portfolio of high-tech materials businesses. As the founder of Helio Additive, David continues to tackle complex problems in the field of 3D printing. He is also the author of the 3D-printing science fiction novel, "Complexity is Free". With a deep understanding of the intersection of business and technology, David offers a unique perspective on the future of digital manufacturing.

Speaker/s

What is it about?

The use of cadavers for medical education and training is becoming more and more questionable due to hygiene and ethics.
We offer alternatives to human and animal cadavers that replicate specific pathologies and are constantly available and reproducible.
The realistic model is built from CT and/or MRI patient data, digitally modified and produced using a multi-material 3D printer. This is the only way to ensure a realistic look and feel as well as being able to use the same surgical instruments on the model as you would during a procedure.
I will present several models, offer a completely new level of practical and realistic development, testing and demonstration of medical devices for companies and scientific institutions worldwide. For the first time, medical models can be produced that replace standard plastic models with authentic anatomical precision and original haptics.

Speaker/s

Professional background:

1997 – 2006
Full service advertising agency in Magdeburg
Head of agency and partners
Revenue responsibility € 1.4 million
Management responsibility for 15 employees

since 2007
Independent consultant for marketing and strategic orientation of companies
Listing of Science and Technology Advisors of the Investment Bank Sachsen-Anhalt
Member of the advisory pool of the state of Saxony-Anhalt

since 2008
Foundation of the company Simon 3D Reproduktionen in Potsdam, focusing on historical, cultural and architectural reproductions

since 2015
Founding of the company S3D Repro GmbH in St. Pölten in Lower Austria 20% shareholder share Responsibilities: ProJet and PolyJet 3D printing technology, 3D scanning, 3D modelling Establishment and expansion of the business unit "S3D MEDICAL"

since 2019
Establishment of the business unit S3D MEDICAL Specialization in multifunctional multi-material models for medical education and training as well as demonstration and training models Data reproduction from CT and MRI data

2022
Preparation of a study on the topic: “Production and application possibilities of true-to-original tactile models for visually impaired people in museum education”

What is it about?

Sustainability is a priority for many manufacturing businesses, and rightly so. The planet needs it to be. Additive Manufacturing offers some promise, but how do we ensure it makes sense over traditional methods regarding sustainability and profitability? Using a couple of example products/components, we will look at the difference in Cost and CO₂e emissions between a range of manufacturing processes, including additive manufacturing, and how the design and material play a huge role in optimizing this balance.

Speaker/s

Alexander Herking is Principal Consultant, Expert Services at aPriori Technologies and holds over 30 years of experience in various roles and industries. Since joining aPriori in 2013, Alexander has led, over the past 10 years, international customer projects for aPriori by supporting manufacturers to unlock cost, manufacturability, and carbon insights resulting in increased product profitability and sustainability.
Prior to joining aPriori Alexander worked in various roles at has software service, Moldflow, Husky IMS, andagon, and Logica.

Speaker/s

What is it about?

The certification of aircraft parts is subject to stringent regulation - the case study demonstrates the certification framework, compliance approach and approval of an exemplary aircraft cabin interior part.

Speaker/s

PROFESSIONAL EXPERIENCE

Aug 21 – date The Aviation AM Centre, Managing Partner

Apr 20 – date AM Global, Director Industrialisation Lead AM Industrialisation Projects, Develop Business for AM in Aviation

Jul 19 – Mar 20 Aviation Consultant, independent

Jan 13 – Jun 19 ETIHAD Airways Engineering, H/o Production, Project Delivery & Innovation P21G Postholder of the EASA approved Production Organization

Mar 12 – Dec 12 ETIHAD Airways Technical, Senior Manager Product Development & Projects

Jan 09 – Feb 12 ETIHAD Airways Technical, Manager Cabin Reconfiguration Program

Nov 06 – Dec 08 EADS and AIRBUS Corporate Audit, Senior Audit Consultant

Oct 03 – Oct 06 AIRBUS Quality, Serial Processes Quality Manager A380 Program

Sep 02 – Sep 03 EADS European Aeronautic Defence and Space Company Trainee in Corporate Young Manager Programme (CYMP) page 1 / 1

STUDIES

Oct 95 – Jun 02 MSc in Engineering (Diplom-Wirtschaftsingenieur) Integrated Manufacturing Engineering and Business University of Paderborn, Germany

Nov 01 – Apr 02 PORSCHE, Stuttgart, Germany Diploma Thesis - Knowledge Management in the Automotive Industry

Apr 01 – Jun 01 RECARO Aircraft Seating, Schwäbisch-Hall, Germany Research Paper - Heat Treatment of aluminium in manufacturing of aircraft seats

Apr 98 – Jun 98 NIXDORF Institute, Paderborn, Germany Supply Chain Management – innovative software solutions

INTERNSHIPS

Jun 00 – Nov 00 MERCEDES BENZ USA, Montvale, NJ

Apr 99 – Jun 99 EADS Military Aircraft Division (GAF RECCE team), Munich, Germany

Nov 98 – Jan 99 BOFROST, Straelen, Germany

Aug 97 – Sep 97 DAIMLERCHRYSLER, Stuttgart, Germany

Jun 95 – Jul 95 STEINHOFF Kaltwalzen, Dinslaken, Germany Languages German - native speaker English – fluent speaking and writing French – fluent speaking and writing Spanish –business conversational

What is it about?

This presentation gives a technologically broad and cross-industry overview of the state of the art in post-processing and quality assurance. Specific case studies will be used to highlight what can be achieved in combination with additive manufacturing and suitable post-processing and process monitoring equipment. One example will be the production of a pure copper component from the field of medical technology, which contains structures with a thickness in the range of a human hair. For process monitoring, an overview will be given of what can be achieved today with low- and high-cost equipment.

Speaker/s

Prof. Seidel’s current positons are:

• Full Professor for “Manufacturing Technologies and Additive Manufacturing” (since 09/19) and Head of Smart Manufacturing Lab (since 07/20) at Munich University of Applied Science
• Head of Additive Manufacturing (since 03/18) at Fraunhofer Institute for Casting, Composite and Processing Technology IGCV
• Management Consultant for Additive Manufacturing (since 12/14)
• Chairman of ISO Technical Committee 261 “Additive Manufacturing” (since 01/19)
• Appointed expert in steering committees of DIN and VDI to coordinate standardization activities in the field of AM and manufacturing technologies in general

From 03/18 to 09/19 he served as Director “Strategy and Institute Development” and from 07/14 to
03/18 as Head of Department “Components and Processes” at Fraunhofer Institute for Casting, Composite and Processing Technology IGCV. From 04/16 to 02/22 he served as Chairman to German Association of Engineers (VDI) Committee on “Environment Health and Safety Issues in Additive Manufacturing”. He studied Mechanical Engineering at University Stuttgart, Technical University of Munich (TUM), and Stellenbosch University (South Africa). He received a doctorate from TUM for his Doctoral Thesis in the field of Powder Bed Fusion and served as part of the Management Board at Institute for Machine Tools and Industrial Management (iwb) of TUM while he was in charge of the “TUM-Cluster for Additive Manufacturing”.
He gathered industry experience at Gebr. Heller Maschinenfabrik GmbH (machine tool manufacturer, Nuertingen, Stuttgart area) and MTU Aero Engines (aero engine components manufacturer, Munich) before joining Fraunhofer in 2014.

Speaker/s

What is it about?

Additive Manufacturing offers exciting new possibilities for designing structural and functional components. Due to the low quantity of products in space industry, there are promising applications for satellites. The benefits of functional integration, mass and cost reduction are the main drivers for considering AM as an alternative to conventional manufacturing methods.

The presentation illustrates OHB's approach to developing and manufacturing AM components. In particular, the requirements for the verification of AM processes are highlighted for Laser Powder Bed Fusion (L-PBF), based on the standard of the European Cooperation for Space Standardization (ECSS). Testing and verification methods based on witness samples, destructive and non-destructive testing as well as surface treatments for opto-mechanical components are discussed. Recently developed AM parts are presented to demonstrate the advantages of AM over machining.

Speaker/s

As Technology Coordinator, Dr. Marco Mulser coordinates the development & implementation of Additive Manufacturing at OHB System AG in Bremen since 2018. He established OHB's AM design & engineering capabilities and coordinates the manufacturing with OHB’s external suppliers for AM parts. Before his recent position at OHB, he was working for the Fraunhofer Institute for Manufacturing Technology and Advanced Materials. He holds a PhD in Production Engineering with a focus on Materials Science.

What is it about?

Additive manufacturing offers nowadays the ability to produce increasingly large parts. However, the post-processing of these parts presents several challenges, especially in the aerospace industry, where stringent requirements must be met. This presentation provides insight into the process chain for manufacturing radio frequency antenna parts for satellite communication. The challenges in the production of these parts include the additive manufacturing process itself, where the parts nearly fill the entire build chamber. Furthermore, milling the parts to precise tolerances relative to the as-printed geometries. Additionally, handling the parts between process steps and shipping them safely to the end customer are crucial aspects of the post-processing stage.

Speaker/s

Studies 2009-2016
Technical University Dresden: Department of Mechanical Engineering
Focus areas: Production technology, machine tool development, methods of virtual product development

Research 2016-2018
Technische Universität Dresden: Institute for Machine Tool Development and Control Engineering
Main topics: Design of forming tools, machine simulation (MKS, FEM, DBS), Generative manufacturing processes

Change to the industry 2018
Urwahn Engineering: Innovative manufacturer of additive manufactured bicycles
Focus areas: Production monitoring and planning, quality assurance, qualification of additive processes for serial production

Change to Oerlikon 2019
First Operational Quality Management: Quality Management and Quality Planning, Complaints Management and Measure Monitoring, KPI Determination and Business Intelligence
Since 2021 Project Manager AM: Project Management, Start-up Management and Efficiency Improvement, Development of Process Chains

What is it about?

At Neue Materialien Fürth, we transfer fundamental university research into industrial application. With our novel prototype PBFEB machine manufactured by probeam GmbH & Co. KG, we are able to process Ti based alloys and titanium aluminides without processing gas in vacuum conditions up to 1100°C. The prototype is capable of 150 kV acceleration voltage and 45 kW power and is equipped with electron optics (ELO) for insitu process monitoring. The higher acceleration voltage compared to conventional machines (60 kV) is beneficial for
pre heating and melting, shortening process times and enabling advanced scanning strategies.
As a result, the efficiency of the process and the final part quality is increased. The machine is controlled by software developed by the chair of Materials Science and Engineering for Metals at the Friedrich Alexander Universität , enabling full control over every single scan line. The ELO allows insitu monitoring of every single layer for defects, contamination or geometrical inaccuracy. This talk will explain, how the next generation of PBF EB machines will benefit froma higher acceleration voltage and insitu process monitoring vi a electron optics, making a huge step toward the broad industrialization of the technology.

Speaker/s