Dr. Katja Böhler - State Secretary of Research, Innovation and Business Development
de
Opening (State secretary Köhler)
Speaker/s
09:20-09:50
Keynote: Additive manufacturing in e-drive
LIVE-STREAM (eng + de) Additive manufacturing in the field of e-drive
Falk Heilfort // Porsche AG
de
Keynote: Additive manufacturing in e-drive
Additive manufacturing offers great potential in the automotive industry in the area of product and process innovation as well as for new business areas. Examples of product innovation are lightweight construction and function integration. In the area of process innovation, agile development and flexible production, for example, are potentials. New business areas are individualization, new offers for customers, spare parts, classic, etc. Additive manufacturing can also contribute to reducing development cycles and increasing product maturity through very quick availability of prototypes.
In the field of e-drives, the potential of additive manufacturing is being investigated and evaluated. Porsche was able to demonstrate potential both in the product and for the development processes in a highly integrated electric powertrain. By applying the new design methods, it was possible to double the stiffness of the drive unit while reducing the mass by around 10%. Thermal management was also significantly improved by integrating a gearbox heat exchanger. By integrating twelve components, 30 screws, twelve seals and various other parts were saved. This not only brings advantages in the package, but also significantly reduces assembly effort. These measures reduced the production time by almost 20 minutes. Furthermore, the use of copper as a material creates interesting concepts that offer high potential for electric machines. The topic of cooling can also be raised to a new level for pulse inverters and machines.
Speaker/s
Dipl.-Ing. Falk Heilfort Porsche AG Project Manager
Profile: experienced development engineer in the field of drives Advanced engineering with a focus on lightweight construction and additive manufacturing
Experience:
07/2013 – today Development Engineer Dr. Ing. h.c. F. Porsche AG, Weissach Project management lightweight construction, additive manufacturing Development of electric drives Development of dual clutch transmissions
07/2006 – 08/2008 Mechanic Porsche Center, Dresden
Speaker/s
09:50-10:20
Keynote: Additive manufacturing @ Airbus Helicopters an opportunity and a challenge
LIVE-STREAM (eng + de)
Frank Rethmann // Airbus Helicopters
de
Keynote: Additive manufacturing @ Airbus Helicopters an opportunity and a challenge
The additive manufacturing process has many interdependencies that have to be aligned to generate a profitable business. The close collaboration between all internal and external contributors is one key aspect to succeed in the industrialization of an aviation part. The challenges and opportunity of this intertwined working process will be shown along Airbus Helicopters additive manufacturing journey.
Speaker/s
Frank Rethmann Airbus Helicopters Deutschland GmbH HoD Industrial Service Center 3D Printing
Frank joined Airbus Helicopters, what was then Eurocopter, in 2002. After some design roles in Engineering, he managed the NH90 configuration team in Donauwörth and Marignane for 10 years. He joined the operations team in 2016 where he was responsible for the performance& improvement department. This is where the first metallic 3D printer was purchased. Since 2020, he has been responsible for the Industrial Service Center 3D Printing.
Tagung der Medienzentren (geschlossene Veranstaltung)
Digitale Werkzeuge in der Schulausbildung
Dr. Anita Stangl // MedienLB
de
Tagung der Medienzentren (geschlossene Veranstaltung)
Speaker/s
3D Printing Conference
Polypropylene - The material of choice for extrusion-based 3D printing
Prof. Dr. Hans-Werner Schmidt // PPprint GmbH
de
3D Printing Conference
Obwohl Polypropylen (PP) zu den weltweit meistverwendeten Polymeren gehört, wird es im 3D-Druck noch nicht umfassend eingesetzt. Grund dafür sind Probleme im Zusammenhang mit der Schichtenhaftung, dem Verzug, der Bettadhäsion und dem Fehlen eines geeigneten Stützmaterials.
PPprint, der Spezialist für den 3D-Druck mit Polypropylen hat diese Problemstellungen gelöst und bietet ein abgestimmtes Produktportfolio für die additive Fertigung mit PP an.
Dabei besteht das Produktportfolio aus Polypropylen 3D-Druck Materialien mit optimiertem Verzug und eine hoher Verbundfestigkeit zwischen den Schichten. Diese sind in einer Vielzahl von Farben erhältlich. Zusätzlich wird durch die speziell für PP entwickelte 3D-Druckoberfläche ein zuverlässiger 3D-Druck von PP-Komponenten und eine rückstandsfreie Entnahme des Produkts ermöglicht. Mit dem weltweit einzigen Stützmaterial für PP, das die Produktion von komplexen Geometrien ermöglicht, wird das Komplettpaket abgerundet.
Prof. Dr. Hans Werner Schmidt wird in dem Vortrag einen Einblick in die Materialentwicklung für den 3D-Druck mit Fokus auf dem Werkstoff PP geben und dabei das Komplettpaket der PPprint GmbH präsentieren.
Speaker/s
Prof. Dr. Hans-Werner Schmidt // PPprint GmbH
10:20-10:50
Keynote: Formula 1 technologies keep automotive history alive.
LIVE-STREAM (eng + de)
Fabian Gafner // Sauber Engineering AG
de
Keynote: Formula 1 technologies keep automotive history alive.
When the legendary Ferrari 340 America Barchetta was built in Modena in 1950, no one could have dreamed of the history this vehicle would experience. The car was one of the very first Ferraris imported to Switzerland. Today it is the only one of two originals in the world that is always kept in operation. This one, 70 years later, had a sudden failure of the rear axle differential housing due to age and stress. Thus began a long but unsuccessful search for a replacement part started. Was this the end for this great piece of automotive history?
We at Sauber Technologies AG took on this challenge. Using 3D scanning and state-of-the-art designing methods, we reverse-engineered the outer geometry and reproduced it using additive manufacturing. And even better: after the investigation by our specialists a possible cause of the damage was found. The design freedom of additive manufacturing was used to give the transmission the durability to ensure that this driving legend will be around for many generations to come.
As one of the most deserving Formula 1 teams, it is our claim to make the knowledge, experience and expertise gained in over 50 years of company history, from development to manufacturing, also available to companies outside the pinnacle motorsport. As a young company with a long tradition, we work day after day for the success of our customers. Just like in Formula 1, we form a real unit as a team and feel at home where many others give up. The core of our expertise lies in particular in lightweight construction and in the additive manufacturing of metal as well as plastic parts. In doing so, we try to push the boundaries and generate real added value with a high degree of expertise and creativity.
Speaker/s
Fabian Gafner Sauber Technologies AG Head of Engineering
After completing his master's degree in mechanical engineering at ETH Zurich, Fabian Gafner dedicated himself to racing as an engineer. He joined the «Sauber Group» in 2014. As a Composite Engineer, he worked in the motorsport department on lightweight designs and structural carbon parts. In 2018, he was able to move internally to the newly founded company «Sauber Technologies AG», which has set itself the task of bringing Formula 1™ technologies to the outside world and making them accessible to external companies. Since then, he has been responsible for customer projects as Head of Engineering with a focus on lightweight construction, composites and additive manufacturing.
Tagung der Medienzentren (geschlossene Veranstaltung
Digitale Werkzeuge in der Schulausbildung
Dr. Anita Stangl // MedienLB
de
Tagung der Medienzentren (geschlossene Veranstaltung
Speaker/s
3D Printing Conference
Are you still milling or already printing?
Joachim Kasemann // Mark3D
de
3D Printing Conference
Werkzeuge und Vorrichtungen können häufig nur bedingt additiv gefertigt werden, weil meistens nicht die benötigte Festigkeit erreicht wird. Durch abriebfestes PA6, dass mit Endlosfasern aus Glasfaser, Kevlar oder Carbon verstärkt wird, kann damit ein besseres Festigkeits-Gewichts-Verhältnis als Aluminium erreicht werden. Jetzt können echte Probleme gelöst und Bauteile gedruckt, die bisher mechanisch gefertigt werden mussten. Durch die geänderten Fertigungsprozesse können Bauteile wesentlich leichter gefertigt werden, oft ohne additiv gerecht zu konstruieren.
Speaker/s
Joachim Kasemann // Mark3D GmbH
10:50-11:40
Panel Discussion: How can AM help to achieve a faster broad market breakthrough?
LIVE-STREAM (eng + de)
Moderation: Bernhard Langefeld // Roland Berger
Falk Heilfort // Porsche AG // Head of Project
Frank Rethmann // Airbus Helicopters // HoD Industrial Service Center 3D Printing
Fabian Gafner // Sauber Engineering AG // Head of Engineering
Christoph Hauck // toolcraft // Manager
Prof. Dr. Johannes Henrich Schleifenbaum // RWTH Aachen University //
Christian Reinhardt // BASF 3D Printing Solutions GmbH // Business Development Manager Transportation
de
Panel Discussion: How can AM help to achieve a faster broad market breakthrough?
Speaker/s
Christian ReinhardtFrank RethmannFalk HeilfortFabian GafnerChristoph HauckProf. Dr. Johannes Henrich Schleifenbaum
Tagung der Medienzentren (geschlossene Veranstaltung)
Digitale Werkzeuge in der Schulausbildung
Dr. Anita Stangl // MedienLB
de
Tagung der Medienzentren (geschlossene Veranstaltung)
Speaker/s
3D Printing Conference
MOIIN Resins- CDB technology for highest precision in DLP/SLA/LCD printing
Anna Babel Drusenthal and Dr. Felix Wöhrle // MOIIN Resins/ DMG Digital Enterprises SE
de
3D Printing Conference
With the previous technological possibilities, smaller or larger deviations in the 3D printing result with photopolymers always had to be expected. The so-called Z-overcuring phenomenon occurs particularly with clear materials and can represent a significant deviation, especially when realising exact inner structures and cavities. The new CDB technology, which was developed by the MOIIN team at DMG Digital SE in Hamburg, enables a major step towards precision and process reliability. CDB stands for "Cure Depth Barrier". It describes the minimised overcuring of the 3D printing resins in the Z-direction - resulting in maximum precision in all dimensions of the printed objects. In an interdisciplinary research project with Deutsches Elektronen Synchrotron DESY in Hamburg, it was successfully proven that 3D printing in the micron range is possible with the help of the CDB technology used. Required miniature capillaries with an inner diameter of approx. 1 mm and a wall thickness of only 100-200 microns could be printed precisely with MOIIN Tech Clear to accelerate or deflect electron beams with terahertz radiation.
Speaker/s
Anna Babel Drusenthal and Dr. Felix Wöhrle // MOIIN Resins/ DMG Digital Enterprises SE
11:40-13:00
Lunch Break
Lunch Break
Speaker/s
Tagung der Medienzentren (geschlossene Veranstaltung)
Digitale Werkzeuge in der Schulausbildung
Dr. Anita Stangl // MedienLB
de
Tagung der Medienzentren (geschlossene Veranstaltung)
Speaker/s
13:00-13:30
Automotive & Mobility
LIVE-STREAM (eng + de)
Motorcycle applications enabled by "industrial" DLP
Florian Fischer and Dr. Klaus Stadlmann // KTM Technologies + GENERA
de
Automotive & Mobility
KTM Technologies arises as development service provider within the KTM Group and for third party customers. Additive Manufacturing with polymers is one of the core competencies. Most important for our development projects are Additive Thinking, the engineering and design of parts tailored for one specific printing process, and the exploitation of new product applications by means of Additive Manufacturing. With our experience and the need by WP Suspensions, the primary design of a motorcycle part could be optimized for DLP-printing. Through the cooperation with GENERA and Henkel Loctite it was possible to select a photopolymer that meets all demands. By generating a requirement specification and testing process for additive manufacturing parts, it was possible to start the series production of the first motorcycle part with photopolymers.
Speaker/s
Florian Fischer GENERA + KTM Technologies Project Lead Additive Manufacturing
Professional background: Mar 2019 – today KTM Technologies GmbH, Salzburg - Project Lead Additive Manufacturing - Group Lead Additive Manufacturing - Senior Engineer Additive Manufacturing Apr 2017 – Feb 2019 EOS GmbH in Krailling, Munich - System Engineering – System Design Polymer - Tech. Project Lead Taskforce - Machine and Application Support Polymer Nov 2014 – Jun 2016 Maritim Film GmbH in Munich - Development of camera equipment - Assistant to the production manager
Educational background: Sep 2014 – Apr 2017 Hochschule München Master Study of Micro- und Nanotechnology - Projekt study at EOS GmbH – advance development - Master thesis at EOS GmbH – advance development Sep 2010 – Jul 2014 Hochschule München Bachelor Study of Physical Engineering - Practical semester at Airbus Helicopters AG – CH53 & FTH Eng. - Bachelor thesis at Airbus Helicopters AG – Loads and Flight Mechanics - Working student at Airbus Helicopters – Dynamic System Architecture
Dr. Klaus Stadlmann GENERA + KTM Technologies Geschäftsführer
12/2015 – Present Founder/Managing Director, Genera Printer GmbH Ernst & Young (EY) Entrepreneur of the Year 2020 Finalist in Startup category 05/2013 – 09/2015 Founder/Managing Director, Way to Production GmbH Successful development and market launch of the SolFlex 3D printers 1 2/2011 – 05/2013 Consultant at Dreve Development of a 3D printer based on the Dual Phase Fabrication (DPF) technology
2008 – 2011 Doctorate Topic: Fabrication of waveguides using two photon lithography Graduated with honors Admission to the Profile High Potential program 06/2010 – 12/2010 Project Design of the world‘s smallest DLP based 3D printer TED-Talk “The world’s smallest 3D printer “ 2003 – 2008 Undergraduate Education TU-Wien, Mechanical Engineering Thesis: Development of an orthosis to support and measure the moment curve of the ankle in rehabilitation Graduated with honors 2001 – 2002 School Education HTL-Mödling, Mechatronics Thesis: Development of a fine adjustment and calibration device for a home cinema projector from Philips Graduated with honors
Medical, Dental & Orthopaedic Technology
Printing implants in the clinic – challenges and opportunities
Prof. Dr. Ute Schäfer // Universitätsklinik für Neurochirurgie, Medizinische Universität Graz
de
Medical, Dental & Orthopaedic Technology
3D-printing of implants, tools or prostheses in a clinical setting is a highly challenging field in additive manufacturing. It is crucial to guarantee patients as well as attending physicians at any time the highest possible quality of material as well as printing process and this quality of course has to be reproducible and on the highest possible level. These requirements in the highly sensitive medical setting are challenging and a broad range of preclinical investigations have to be done, before 3D-printed can be included to the clinical routine. The COMET K-Project CAMed funded by two Austrian public institutions aims to bring the highly promising technology of 3D-printing into a clinical setting to optimize treatment options by manufacturing patient-specific implants. In the first project years of CAMed, optimal printing parameters for various promising materials were developed, printed samples were analysed on their mechanical characteristics by bending and charpy tests as well as on their clinical sterilizability and biocompatibility. Together with segmentation and simulation of patient data and a close cooperation with scientific partners for process development and optimization, the chance of integrating 3D-printing into the clinic within the next years is getting closer and closer.
Speaker/s
Prof. Dr. Ute Schäfer Universitätsklinik für Neurochirurgie, Medizinische Universität Graz Head of the Research Unit for Experimental Neurotraumatology Scientific Director of the COMET K‐Project “CAMed”
Ute Schäfer has been head of the Research Unit for Experimental Neurotraumatology since 2008. Since 2018, she has also been Scientific Director of the COMET K‐Project “CAMed” (Clinical Additive Manufacturing for Medical Applications) and head of the newly established Medical 3D‐Printing Lab at the University Clinic Graz, which is unique in Europe. The aim of the project as well as of the Medical 3D‐Printing Lab is to establish various 3D‐printing technologies directly in the clinic to be able to additive manufacture individualized implants, models and tools inhouse for optimized patient treatment. Further fields of expertise are cell biology, stem cell differentiation, cell replacement therapies, molecular biology, (cerebral) inflammation and various animal models. It is our vision to print patient‐specific parts whenever necessary at some point in the distant future and in this way to guarantee each patient an individual, optimized treatment.
Vortrag über die Möglichkeiten der dezentralen Fertigung (modulare Containerfabriken), sowie die Vorstellung passender Softwareentwicklungen mit Integration einer NFT-basierenden Blockchain-Technologie zum sicheren Austausch von Produktionsdaten.
Speaker/s
Daniel Beck // Bionic Production GmbH
13:30-14:00
Automotive & Mobility
LIVE-STREAM (eng + de)
Industrialization of the AM process chain for automotive production
Dr. Felix Haeckel // BMW AG
de
Automotive & Mobility
Based on the previous L-PBF series applications of the BMW Group, the results of the BMBF-funded project IDAM (Industrialization and Digitization of Additve Manufacturing) will be presented. In particular, the highly automated design of the production line and the associated cost reduction will be discussed. To conclude the derived interface descriptions are presented.
Speaker/s
Dr. Felix Heackel BMW AG
1988, born in Munich 2014 M.Sc in. Civil Engineering at the Technical University of Munich (TUM) 2014 - 2017 PhD Student at the BMW Group / RWTH Aachen Topic of the Thesis: „Reproducibility of Laser Powder Bed Fusion“ 2017 - 2020: Project Manager Quality Additive Manufacturing Metal, BMW Group 2020 – 2022: Project Manager Predevelopment Additive Manufacturing, BMW Group Project Manager IDAM (BMBF funded)
Medical, Dental & Orthopaedic Technology
Pioneering the future: Micro Additive Manufacturing
Avi Cohen // Nano Dimension
de
Medical, Dental & Orthopaedic Technology
The ever growing need for precise micro-parts is restricted by current technological limitations. A next generation technology enables sub-micron accuracy and surface finish combined with a set or precision materials marks a new age in digital mass manufacturing. So, whether you manufacture medical devices, molds, inject parts for your customers or develop your own product in-house, getting the perfect part fast is a pivotal step forward. The key to the success of the next generation technology is that it brings the benefits of AM to micro manufacturers for the first time, including hitherto impossible part complexity (enhancing design and functionality), no tooling costs, minimal set up costs, and the ability to mass customize and personalize products. While this new-gen technology can cater for high volume applications, the introduction of a 3D printing solution for micro manufacturers also means that companies are able to reduce the reliance on economies of scale, as the technology makes full production runs measured in thousands as inexpensive as producing one.
Speaker/s
Avi Cohen Nano Dimension EVP Sales
Avi is one of the exceptional 3D Printing Evangelists who has spent over 23 years in the industry, and is recognized as an AM technology leader. At Nano Dimensions, he is leading the global sales for fabrica; brining rich understanding of the business environment of customers, partners & channels.
Avi has spearheaded product innovation, driving customer adoption in the 3D Printing and Additive manufacturing domains, since his 1999 tenure at Stratasys (formally Objet Geomotries) where he was leading and paving the healthcare applications, following 5 years as VP at Xjet (metal and ceramic AM). He is an industry veteran with over two decades of senior leadership experience, Avi is currently responsible for driving company global sales at fabrica.
There is no such thing as impossible - Additive (series) manufracturing requires customized
Dr. Johannes Lohn // PROTIG GmbH
de
3D Printing Conference
Addittive Fertigung bietet ein enormes Potenzial für industrielle Anwendungen durch eine signifikante Steigerung der konstruktiven Gestaltungsfreiheit. Um diese Freiheitsgrade vollumfänglich nutzen zu können bedarf es der Qualifizierung neuer Werkstoffe für die Additive Fertigung, um der Nachfrage des Marktes gerecht zu werden. PROTIQ legt einen großen Fokus auf die Entwicklung innovativer Materialien, welche in der Industrie als "nicht verarbeitbar" gelten. So ist es PROTIQ bereite 2011 gelungen, einen einzigartigen prozess zu entwickeln, mit dem Kupfer additiv verarbeitet werden kann. Da Kupfer die Strahlung herkömmlicher Laserschmelzanlagen zu einem großen Teil reflektiert, werden häufig Legierungen mit einer geringen Leitfähigkeit verwendet. Mit der innovativen Kupferlegierung war PROTIQ der erste Anbieter, der beispielsweise Induktoren in höchster Qualität produzieren konnte. Auf dieser Basis wurde der Prozess kontinuierlich optimiert. So kann bei PROTIQ nunmehr ebenfalls 100% reines Kupfer im 3D-Druck prozessiert werden. Einen weiteren interessanten Anwendungsbereich öffnet der Werkstoff Zink. Bauteile aus der Zinklegierung Zamak 5 als etabliertes Standardmaterial für den Zinkdruckguss sind weit verbreitet. PROTIQ ist es als weltweit erstem Anbieter gelungen, einen Prozess zur additiven Verarbeitung des Serienwerkstoffs Zamak 5 zu entwickeln, mit welchem die für den Zinkdruckguss typischen hohen Zeit- und Kostenaufwände überwunden werden. Prototypen sowie Kleinserien entstehen so zu einem vergleichsweise geringen Bauteilpreis.
Speaker/s
Dr. Johannes Lohn // PROTIG GmbH
14:00-14:30
Automotive & Mobility
LIVE-STREAM (eng + de)
Industrialization and Digitalization of the AM process chain for series production of components from the automotive industry
Sebastian Blümer // GKN Additive
de
Automotive & Mobility
Additive Manufacturing has the potential to change today’s production strategies and thus to streamline process chains in the automotive industry. However, the cost-sensitive production environment requires new industrialization concepts that significantly reduce the unit costs of additively manufactured components. As part of the IDAM research project (Industrialization and Digitization of Additive Manufacturing for Automotive Series Processes), the L-PBF process is being enabled for industrialized series processes for the first time. The focus of the project is on the entire AM process chain, starting with powder conditioning, through manufacturing to post-processing of the additive components. For this purpose, a fully automated production line was set up in the form of a modular machine concept. The subsequently implemented connection between plant hardware and digital plane (e.g. MES/ERP systems) offers the possibility to monitor production processes. The implemented solution concept for automation in combination with the modular approach of the process chain makes it possible to further reduce the amount of manual work and thus achieve a significant reduction in unit costs. The key topics of the presentation are the developed industrialization concept, the technical implementation in a demonstrator as well as the results and their evaluation based on test sequences.
Speaker/s
Sebastian Blümer GKN Additive Technology Manager Laser AM
Sebastian is a communicative, open-minded engineer interested in future technologies with a passion for Additive Manufacturing. For the last 8 years he has been working on various challenges (design, process qualification, post-processing strategies, industrialization) in the AM industry. Today, his main focus is on the industrialization of metal additive manufacturing, especially Laser Powder Bed Fusion. As part of the IDAM research project, he was involved in topics such as material flow simulation, factory planning, development and improvement of Multilaser-Strategies, and automation of system hardware to further increase the level of industrialization.
Medical, Dental & Orthopaedic Technology
Silicone Additive Manufacturing - The next material revolution in AM
Dr. Manuel Schaffner // Spectroplast
de
Medical, Dental & Orthopaedic Technology
This is the first time silicones have been made available in the world of additive manufacturing. Silicones are the material of choice when it comes to healthcare and medical devices. With the advent of additive manufacturing, silicone is now opening up exciting opportunities in the healthcare and medical sectors to improve the lives of patients around the world.
Speaker/s
Dr. Manuel Schaffner Spectroplast AG CEO and Founder
Dr Manuel Schaffner holds a PhD in materials science from ETH Zurich. During his studies at Harvard / ETH, he developed Silicone Additive Manufacturing, the world's first high-precision additive manufacturing technology for industrial and medical silicones. Additive silicone manufacturing is paving the way for life-enhancing and life-saving custom silicone devices with a positive impact on people's lives all around the world.
3D printed cranial plates in PEEK - cost savings, resource-efficient and backed up with regulatory data
Martin Herzmann // Kumovis
de
3D Printing Conference
Die Herstellung von individualisierten Schädelplatten hat sich in den letzten Jahren als Behandlungsstandard etabliert, da die Komplikationsrate niedrig und die Patientenzufriedenheit hoch ist. Filamentgedruckte Implantate für MKG und Neurochirurgie werden immer attraktiver, da die Material- und Produktionskosten erheblich gesenkt werden können. Die Hersteller von Medizinprodukten müssen mit qualifizierten Maschinen arbeiten und die gesetzlichen Anforderungen erfüllen. Folglich müssen FDM-gedruckte Implantate den gleichen regulatorischen Weg gehen wie andere Medizinprodukte, insbesondere unter MDR Konditionen. Kumovis liefert regulatorische Daten als Teil einer kommerziell verfügbaren Lösung für gedruckte PEEK-Schädelimplantate. Kumovis hat einen sog. Design-Envelope für patientenindividuelle Implantate entwickelt, der die Mehrzahl der anatomischen Formen und Implantatgeometrien abdeckt. Regulatorische Daten wie biologische Validierung (Zytotoxizität, Sensibilisierung, Implantation, chemische Charakterisierung und toxikologische Risikobewertung) und mechanische Tests von Worst-Case-Geometrien ebnen den Herstellern von Medizinprodukten und Krankenhäusern den Weg zur Zulassung. Die mechanischen Eigenschaften der mit Kumovis-Hardware hergestellten Implantate erfüllen die ASTM/ISO-Normen für die Implantatherstellung.
Speaker/s
Martin Herzmann // Kumovis
14:30-15:00
Automotive & Mobility
LIVE-STREAM (eng + de)
Additive serial applications in the railway business -
manufactured in the international printer network
Dr. Maximilian Kunkel // Siemens Mobility
de
Automotive & Mobility
Siemens Mobility GmbH established an international printer network. The purpose is to produce high-end parts for customers.
Additive manufactured parts are used as spare parts, especially in the case of obsolescence, as innovative parts for new vehicles or for the maintenance in the depots.
At present especially FDM and PBF-L are used as printing technologies to fulfil the high demands in the rail industry.
Speaker/s
Dr. Maximilian Kunkel Siemens Mobility R&D Project Manager & Senior Key Expert AM Technologies
Maximilian Kunkel graduated as Doctor of Engineering at TUT in South Africa and works as R&D Project Manager and Senior Key Expert for AM Technologies at Siemens Mobility GmbH. Next to numerous R&D projects he is leading the task force approval of MgA e.V. and is actively engaged in the development of national and international standards for AM technologies.
Medical, Dental & Orthopaedic Technology
Additive manufacturing as enabler for realistic surgical simulations
Dr. Hannah Riedle // ANAMOS GmbH
de
Medical, Dental & Orthopaedic Technology
ANAMOS develops and distributes 3D-printed configurable anatomical soft tissue models (e.g. heart) on which surgical interventions can be simulated. Surgical simulation is used in medical education and training or in the development of new medical devices and their evaluation. Traditionally, mainly cadavers and animal models are used for this purpose, whose deficits include especially the lack of standardization and the strongly limited selection of anatomical variants and pathological defects. The flexible configurable anatomical models, as an extension of the simulation portfolio, offer a free choice of any desired anatomy and pathology. By representing the complex anatomical geometry in combination with realistic haptic feedback, the models further offer not only 3D visualization, but real functionality in simulation. The generation of realistic, functional models is only possible due to the combination a newly developed digital design process and 3D printing technologies to achieve the original complex geometry. The focus lies on soft, elastic material properties to mimic realistic haptic feedback. 3D printing of elastomers with a Shore A hardness under 30 is still very rare, however human soft tissue properties mostly lie beneath this value. Therefore, ANAMOS encourages the discussion about the need for more and improved 3D-printing technologies for elastic materials
Speaker/s
Dr. Hannah Riedle ANAMOS GmbH Founder
Hannah Riedle, PhD, studied medical engineering at the Faculty of Mechanical Engineering at the Technical University of Munich. From 2015 to 2020, she worked as a research associate in the research sector Biomechatronics of the Chair of Manufacturing Automation and Production Systems at Friedrich-Alexander-University Erlangen-Nuremberg. In her doctoral thesis, she targeted the development of haptic, generic models of soft anatomical structures for surgical simulation. For this purpose, she focused on three interacting research areas: the creation of digital, generic anatomical models, their additive manufacturing as soft, geometrically complex components, and the quantitative and qualitative evaluation of the physical models. Based on her dissertation topic, she founded the start-up ANAMOS in 2020, which develops and distributes configurable 3D printed anatomical models for simulating surgical procedures. Since 2017, Hannah Riedle has also volunteered as a community manager for 3DHeals, an international network for 3D printing in medicine.
Additive copper component connects L-PBF and LMD process
Uwe Schulmeister // toolcraft AG
de
3D Printing Conference
toolcraft ist Vorreiter in zukunftsweisenden Technologien wie der additiven Fertigung in Metall und individuellen Roboterlösungen. Das Unternehmen bietet die gesamte Prozesskette von der Idee über die Fertigung bis zum qualifizierten Teil im Bereich der CNC-Zerspanung, des 3D-Drucks in Metall sowie dem Spritzguss und Formenbau.
Seit 2011 gehört die additive Fertigung in Metall mit inzwischen 13 Anlagen und eigenem AM-Labor zum Leistungsportfolio von toolcraft. Nach gemeinsamer Entwicklung gelang es dem AM-Team bei toolcraft mit dem Maschinenhersteller Trumpf, den ersten industriell eingesetzten grünen Scheibenlaser für Kupfer zu implementieren. Verarbeitet wird auf der L-PBF Anlage neben Reinkupfer auch Cucr1Zr, eine aushärtbare Kupferlegierung mit hohen Festigkeitswerten, auch bei höheren Temperaturen.
Da die Industrie die Bereitstellung großer Bauteile fordert, hat man hierzu nun eine zusätzliche Möglichkeit mittels einer LMD-Anlage geschaffen. Weitere Vorteile von LMD liegen in der Beschichtung von Bauteilen sowie im Aufbringen zusätzlicher Geometrien auf Bestandsteile. Das wiederum bietet im Bereich der Reparatur von Komponenten, als auch in der kosteneffektiven Herstellung von hochverschleißfesten hybriden Bauteilen enorme Vorteile.
In unserem Vortrag möchten wir die beiden AM-Verfahren Pulverdüse sowie Pulverbett mit Kupfer vorstellen und anhand von Bauteilen die additive Prozesskette, die Möglichkeiten sowie die Vorteile aufzeigen.
Innovative (e-)bikes of tomorrow - Serial production with 3D-Printing
Sebastian Meinecke // Urwahn Engineering GmbH
de
Automotive & Mobility
With a passion for design, function and high technologies, we are shaping the urban mobility of tomorrow in a innovative and sustainable context. For our mission, we pair metallurgical 3D printing (SLM) with lean manufacturing for holistic mobility approaches under consideration of complex user needs. In this way, we can create the worlds first E-Bikes, which are mass-produced with 3D printing on-demand and just-in-time in Germany.
Speaker/s
Sebastian Meinecke Urwahn Engineering GmbH CEO & Designer
2013 already founded the first bicycle manufactory alongside his studies 2013 one of the first users of the new ego.incubators -FabLab & additiv+ 2015 EU funding for the project Urwahn Engineering - framework concept by means of AM 2015 Research project in collaboration with citim GmbH - SLM (stainless steel) 2016-18 Research project in collaboration with NRU GmbH - casting x high speed sintering 2017 Spin-off company Urwahn Engineering GmbH 2018 Series production of small parts using AM - injection moulding x MultiJet modelling 2018 Series production of the world's first urban bike using AM - SLM 2020 Series production of the world's first urban e-bike using AM - SLM 2021 Expansion of production to second 3D printing line - Urwahn x Oerlikon 2021 Series production of the world's first gravel (e-)bike using AM - SLM 2021 Expansion of AM technologies - FDM, metal SLS & CLIP 2021+ further scaling & internationalisation
Medical, Dental & Orthopaedic Technology
Demanding geometries in titanium 3D printing in hybrid production for thin-walled patient-individual dental EAP®-Abutments
Prof. Ing. Dr. med. dent. Mario Kern MSc MSc // EAP® Abutments
de
Medical, Dental & Orthopaedic Technology
Dental implants are the gold standard for lost teeth. To attach a dental crown to an implant, it needs a connector. In a previous study, it was found that current couplings (abutments) met either the need for aesthetics or the need for biocompatibility. Both requirements together could not be served. Some of the resins used in modern dentistry are highly toxic, especially those that have good mechanical properties. With EAP® abutments, it was possible for the first time to create a new product category in dentistry that can only be produced economically using 3D printing. Hybrid manufacturing places high demands on data management, accuracy of fit and 3D printing parameters.
Speaker/s
Prof. Ing. Dr. med. dent. Mario Kern MSc MSc EAP® Abutments CEO & Founder
Prof. Ing. Dr. Mario Kern has been active in the dental industry for several years in various functions, including private practice and education. In 2018, he became CEO of EAP® Abutments and is committed to the optimisation processes in additive manufacturing and the implementation of the milling concept. Dr. Kern has been working on cell attachment to dental implant abutments since 2008. In addition to being a dentist, he also has an engineering degree and an MS degree in oral implantology and an MS degree in periodontal therapy.
Serial development and requirements for additive products - Challenges and opportunities
Andreas Knöchel // OECHSLER AG
de
3D Printing Conference
OECHSLER – weltweit Vorreiter auf dem Gebiet der additiven Fertigung – inspiriert seit 2017 mit seinen Lösungen namhafte Kunden in den verschiedensten Märkten. Jetzt schlagen wir ein neues Kapitel auf. In Zusammenarbeit mit anderen Größen der Druckerbranche und der Industrie treiben wir die industrielle Serienfertigung 3D-gedruckter Kunststoffbauteile zügig voran. So lassen sich kleine Losgrößen ebenso zu vernünftigen Stückkosten realisieren wie Großserien und komplexe Bauteile. Auf diese Weise bieten wir unseren Kunden maximale Freiheit in Sachen Design, Funktionsoptimierung und Integration.
Speaker/s
Andreas Knöchel // OECHSLER AG
16:00-16:30
Automotive & Mobility
LIVE-STREAM (eng + de)
The BIG 5 for series metall printing
Stefan Kammann and Markus Schnell // Continental Engineering Services GmbH
de
Automotive & Mobility
Continental is one of the biggest, technological leading and worldwide acting automotive supplier. There are a lot of use cases for additive manufacturing. The big challenge is now to go the 5 steps to series production of printed metal parts. We will give a look into the additive world of Continental with the focus on IATF 16949 and series parts in Aluminum.
Speaker/s
Stefan Kammann Continental Engineering Services GmbH Head of Business Center
Education, University 1994 – 1997, Education TV& Radio Electronics, Score 1.0 1997 – 2003, Dipl.-Ing. Electromechanical Systems, TU Darmstadt, Score 1.3
Professional Career 2003 – 2008, Continental AG: Electrical Engineering, EE Project Lead 2008 – 2009, Continental Engineering Services (CES): Project Manager 2010 – 2016, CES: Senior Manager Chassis & Safety ECU Development 2016 – 2020, CES: Head of Competence Center Additive Design & Manufacturing (ADaM)
Current profession: 2020 – today, CES: Head of Business Center Samples & Mechanical Solutions (including CC Additive Design & Manufacturing)
Markus Schnell Continental Engineering Services GmbH Manager Additive Design and Manufacturing
Education, University 2004 – 2007, Education industrial mechanic Siemens VDO (from 2007 Continental), Grade 1.1 2008, Technical college entrance qualification 2009, Federal Armed Forces 2009, Work and Travel New Zealand 2010 – 2015, Master's degree mechatronics, Technische Hochschule Mittelhessen, Grade 1.0
Professional Career 2015 – 2017, Continental AG, Robotics development 2017 – 2020, Continental Engineering Services: Development Engineer, Additive Manufacturing 2020 to date, Continental Engineering Services: Manager Additive Design and Manufacturing
Medical, Dental & Orthopaedic Technology
Digitizing Craftmanship for a better Healthcare - 3D printed orthopaedic shoe lasts
Dr. Johannes Lohn // Protiq GmbH
de
Medical, Dental & Orthopaedic Technology
3D Printing in orthopedic footwear technology
Bespoke orthopedic footwear typically takes several weeks to manufacture. One of the most critical time factors here is the custom fabrication of the lasts used to make the shoes. This lengthy step can be reduced dramatically with the help of additive manufacturing . Optimized fitting accuracy represents a further advantage, particularly in orthopedics. PROTIQ employs selective laser sintering (SLS) as the 3D printing process for manufacturing the resistant plastic object. The free shoe last configurator makes it possible to create individual 3D last models and integrates the modeling directly into the ordering process.
Speaker/s
Dr. Johannes Lohn Protiq GmbH Head of Development, Marketing & Sales
Johannes Lohn studied mechanical engineering at the University of Paderborn. Following his studies, he worked as a research assistant at the DMRC.As part of his research work on the topic of additive manufacturing, Mr Lohn built up an optimised machine for selective laser sintering and investigated the laser-powder interaction. Today, he represents PROTIQ GmbH as an authorised signatory and is responsible for the areas of development, marketing and sales.
Design of a Compliant Additively Manufactured Rail Brake
Urs Hofmann // inspire AG
de
3D Printing Conference
Zurich - Erfurt: 440 km as the crow flies - as a commute? That could be possible in the future! How? With the Hyperloop. In 20 minutes, this distance can be overcome sustainably! There are many challenges; one of them is emergency braking, e.g., in the event of an unexpected power failure. The brake should be small, lightweight, as well as fail-safe closed. We solved this challenge with a highly functionally integrated additively manufactured monolithic brake. By pressurizing a bellow, a compliant system is forced apart. This generates a gap between the guide rail and the brake. When pressure is released, immediate braking is initiated by contracting the bellow. The integrated gyroid structure absorbs the braking forces and air channels assist in releasing the brake. Our novel design consists of one component, which reduces the number of possible failure points, and its many functions and lightweight design bring the vision of sustainable mobility one step closer.
Speaker/s
Urs Hofmann // inspire AG
16:30-17:00
Automotive & Mobility
LIVE-STREAM (eng + de)
Additive Manufacturing of Pure Copper with Green Laser Light
Michael Thielmann // TRUMPF Laser und Systemtechnik GmbH
de
Automotive & Mobility
Pure Copper applications with maximum material conductivity are a challenge for 3D printing due to the high reflective properties for commonly used laser sources with infrared wavelength in laser powder bed fusion systems. The usage of a 515 nm green laser source overcomes this challenge. The processability from pure copper with a robust process window and an efficient laser process for maximum material conductivity without post processes will be shown. New optimized Applications like electric motor windings for automotive and customized tooling devices like inductors or heat sinks benefit from maximum electrical and thermal conductivity combined with an additive manufacturing design and will be shown exemplary.
Speaker/s
Michael Thielmann TRUMPF Laser und Systemtechnik GmbH Product Manager LMF Process and Process Development
Current Activities
Expert in LPBF
Responsible for Material and Parameter portfolio for TruPrint LPBF systems
Responsible for LPBF process development product management
Expert for processing of pure copper with green laser sources
Work Experience
TRUMPF Laser- und Systemtechnik GmbH, Ditzingen Product Manager Process & Process Development Additive Manufacturing Application & Process Development Engineer
Fraunhofer Institute for Laser Technology ILT, Aachen Process Development high Power Selective Laser Melting
Mercedes Benz, Stuttgart Master Thesis, SLM with 1 kW for Aluminum Alloys
Education
University of applied Science FH Aachen Bachelor of Engineering in Mechanical Engineering Master of Engineering in Construction and Product Development
DVS – German Welding Society SFI/IWE International Welding Engineer
Medical, Dental & Orthopaedic Technology
Individual medical solutions with AM
Andreas Velten // IFA3D Medical Solutions GmbH
de
Medical, Dental & Orthopaedic Technology
Every person is individual, so should the medical care. With the possibilities of additive manufacturing, solutions for complex cases and new supply options can be found in standards. From scanning of the patient with a 3D scan, or CT/MRI/CBMT to the design with modern CAD programs,up to the printing of the mold, or the final supply, real case studios will be used to show what time savings are possible, what advantages are shown by additive manufacturing and where the limits are.
Speaker/s
Andreas Velten Institut für Anaplastologie Velten & Hering Head of R & D
1982-1986 Interned as a dental technician
1989 Escaped from the former GDR
1990-1993 Employed as a dental technician in the Dentallabor Christel home in Schleswig-Holstein
1993-1994 Employed as a sales assistant at Maoro Dental and Dental2000
1994 Established the Velten-Dental-Zentrum GmbH in Genthin
1995 Successful examination for the master craftsman’s diploma at the Meisterschule Halle
1996 Designed the first custom-made solutions for facial reconstruction
1998 Acquisition of the Institut für Epithesen Strunk, which was then continued as the Institute of Anaplastology Velten
1999 Joined medical mission to aid children suffering from radiation of nuclear test debris in Lithuania
2001 Graduated as an accredited anaplastologist
2003 Relocated to Sandau as a CEO of VKT-Velten Kunststofftechnik GmbH (www.vktsandau. com), KV GmbH and KPV GmbH; Handover of the Institute of Anaplastology to Mrs. Daniela Hering and Mrs. Sylvia Velten
2004 Continued as a director of the product development and construction department at VKT GmbH. First experiences in Rapid Prototyping, Tooling and 3D Design
2012 Awarded the economy prize of Altmark by the Prime Minister Dr. Reiner Haseloff
2014 Relocated to Berlin and founded of the Institute for Anaplastology Berlin
2015 Joined the medical mission to aid wounded Syrian war refugees in Turkey www.epithetikprojekt.de
2016 Founded the IFA3D Medical Solutions GmbH
2017 Jurymember 3D Pioneers Challenge
2018 Member of the german 3D Printing Association
2022 Boardmember Technic german 3D Printing Association
Keynote: AM certifications: What is the benefit and what is the effort behind it?
LIVE-STREAM (eng + de)
Christoph Hauck // toolcraft
de
Keynote: AM certifications: What is the benefit and what is the effort behind it?
toolcraft is a pioneer in future-oriented technologies such as additive manufacturing in metal and individual robot solutions. The company offers the entire process chain from the idea through manufacturing to the qualified part in the field of CNC machining, 3D printing in metal as well as injection molding and mold making.
Since 2011, additive manufacturing in metal has been part of toolcraft's service portfolio, which includes 13 systems and its own AM laboratory. Toolcraft as a Tier 1 supplier offers the entire additive process chain in metal in-house, from design and simulation to AM manufacturing and component finishing to optical, tactile an non-destructive testing.
In march 2018, a major milestone was reached with process qualification in accordance with the Nadcap aerospace standard. Therefore, the high requirements of the aerospace industry are also met in the AM area. The preparation for the Nadcap certification took more than 12 months. The presentation gives an overview of the quality assurance possibilities of 3D printing components (metal) along the entire process chain: employee qualification, pre-process and post-process. Special requirements in production, such as environmental protection, occupational health and safety, must also be taken into account.
In our presentation, we would like to highlight the importance and benefits of certifications in additive manufacturing and demonstrate the effort involved based on our own practical experience.
Speaker/s
Christoph Hauck toolcraft AG Marketing / Sales
Managing director since 2012
Member of the Executive Board with focus on new technologies and new markets
Cooperation in committees and associations:
Member of the core competence team AM at BDLI
Member of various DIN standard committees on the subject of AM also for the DIN presidium on the subject of aviation
Main board VDMA
VDMA divisions: Robotics / Automation, Medical Technology
Chairman of the VDMA Working Group "Additive Manufacturing"
Spokesman for the Additive Manufacturing Expert Committee in Bavaria
09:30-10:00
Keynote: The Emerging 8 Technologies - How Technology Convergence Drives Innovation.
LIVE-STREAM (eng + de)
Daniel Büning // nFrontier
de
Keynote: The Emerging 8 Technologies - How Technology Convergence Drives Innovation.
The Lecture will be focussing around the core idea of nFrontier - the believe that impactful next level product innovations will be unleashed by the power of „Eight Essential Technologies“. Emerging Technologies such as: Additive Manufacturing, Virtual Reality, Tactile Robotics and Artificial Intelligence have become state of the art technologies within the context of engineering and design - some of its vast potential has been evaluated and spearheaded by entrepreneurs from the creative fields. nFrontier is an Innovation Studio and Venture Builder from Berlin. The core focus of nFrontier lies in the convergence of those novel technologies - how to intertwine technologies to create the previously unseen - whether it's a virtual experience, a physical object or a hybrid. Within their lab environment - EmTeCe - nFrontier unleashes the creative power of their pioneers team to set up experiments quickly, iterate design ideas fast and fuel the hardware of their amazing partners with cutting edge ideas.
Speaker/s
Daniel Büning nFRONTIER GmbH CEO and Co-Founder
Daniel Büning is an award winning entrepreneur, innovator, researcher, and university lecturer. His work oscillates between digital technology, innovation, culture and politics. He is the CEO and Co-Founder of nFrontier a Berlin based Innovation Studio & Venture Builder which is focussed on the creation of impact driven products by utilizing latest emerging technologies such as: Artificial Intelligence, Additive Manufacturing, Virtual Reality/Augmented Reality, Robotics, Drone Technologies and Quantum Computing. In his daily practice Daniel, deals with scouting, concept development and the execution of innovation projects and their economic implementation into practice. The development of new products, business models and venture Ideas is the core focus of his daily work. Prior to nFrontier he worked 4 years at Bigrep an aspiring high-tech start-up from Berlin. In 2016 his studio NOWlab, which he co-founded in 2014 was acquired by Bigrep -with NOWlab | The BigRep Consultancy, a unique innovation and creative hub full of dynamics and synergies was created within the technology company which he lead as a managing director. In his last Role as CIO he was overlooking the all the innovation activities of the company especially in the domain of foresight, research projects and strategic technology partnerships. Beyond his innovation role he was majorly involved in all stages of the strategic planning and execution of the successful fundraising process that secured the raise of EUR 35 million in venture capital to date. The investors won include Körber AG, BASF, Klöckner & CO SE., and the Koehler Paper Group. His strategic partnerships include e.g. Etihad Airways, Ford, Bosch Rexroth within the industry sector as well as e.g. MIT Boston, RWTH Aachen, DMRC Paderborn and TNO Eindhoven. In November 2019, he was voted "Top 40 under 40" by the leading German business magazine Capital in the management category. His work has been awarded numerous prizes and grants: SDV Studienstiftung des Deutschen Volkes, Fulbright Commission, FES Friedrich Ebert Foundation, MEXT grant from the Japanese government. Daniel is also a fellow of the federal government's center of excellence for cultural and creative industries.
3D Printing Conference
„Wire-based 3D Printing – Technological Potential and Application Opportunities“
Dr. Ines Dani // Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU
de
3D Printing Conference
Seit einigen Jahren wird verstärkt an Verfahren zur Nutzung von metallischen Drähten als Ausgangsmaterial für 3D-Druckverfahren geforscht. Drahtförmige Materialien sind deutlich preiswerter und handhabungsfreundlicher als Pulver sowie in sehr hoher Materialvielfalt kommerziell verfügbar. Im Unterschied zu pulverbettbasierten Prozessen ist die Fertigung von Bauteilen mit gradierten oder diskreten Materialübergängen möglich. Stützstrukturen können durch mehrachsige Bewegungssysteme vermieden werden. Als Energiequellen werden dabei sowohl Laser als auch Lichtbogen (-plasmen) und die Induktion eingesetzt. Ziel des WirePrint-Netzwerks ist es, den technologischen Reifegrad drahtbasierter additiver Fertigungsprozesse zu erhöhen und neue Einsatzgebiete zu erschließen. Dazu bringt das Netzwerk Unternehmen und Forschungseinrichtungen aus den Bereichen Material, Anlagentechnik, Qualitätssicherung, Technologieanwender und Endnutzer der hergestellten Bauteile zusammen, um Erfahrungen auszutauschen, gemeinsam Konzepte sowie zukunftsfähige Technologien und Produkte rund um den drahtbasierten 3D-Druck zu entwickeln. Damit wird es den Partnern ermöglicht, ihr Produkt- und Leistungsportfolio weiter zu qualifizieren und gemeinsam die beste technologische Lösung für die jeweilige Anwendung anzubieten. Schwerpunkt ist, komplexe und technologisch anspruchsvolle Wertschöpfungsketten mit hohen eigenen Leistungsanteilen in Deutschland und Europa zu realisieren. Durch die Vernetzung von Forschung, Entwicklung, Transfer, Produktion und Service werden vorhandene Potenziale und Kompetenzen von Wissenschaft und Wirtschaft mit Hilfe des Netzwerkmanagements zusammengeführt.
Speaker/s
Dr. Ines Dani // Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU
10:00-10:30
Design
LIVE-STREAM (eng + de)
The path to fully automated design workflows
Dr. Ole von Seelen // trinckle 3D GmbH
de
Design
The entire AM world is aiming to realize more and more scalable series applications. The focus is mostly on low-volume production and individualization - combined with design processes that have to be repeated frequently.
Considering this situation, it is worth taking a look at the status quo of the software landscape. On the one hand, there is classic CAD software, which represents all-rounders, but only allows a low degree of automation and requires expert users.
On the other hand, there is an increasing number of software products that specialize in specific process segments and sometimes also provide automation. However, here, too, an expert is required who must manually link the process segments.
Dr. Ole von Seelen demonstrates the need for 100% automated design processes in order to achieve scalable AM applications, using a number of industry examples. He also illustrates with some practical examples which design functions can be well automated by algorithms and how this makes AM technologies more accessible.
Speaker/s
Dr. Ole von Seelen trinckle 3D GmbH Head of Business Development & Strategic Marketing
Dr. Ole von Seelen is responsible for marketing, sales and business development at trinckle. He studied business administration in Germany and Sweden, received his PhD in B2B Marketing at the University of Münster before joining the young trinckle team in 2014.
Software & Processes
Supply chain potentials: On-Demand Production with additive manufacturing
Jochen Loock // DB Schenker
de
Software & Processes
The effect is well known: In the second half of a product life cycle, the production demand is generally decreasing. Nevertheless, companies are obliged to supply their customers with spare parts. For manufacturers, this means an economic dilemma. Despite the low demand, the conventional production goes along with high minimum order quantities. The result: high storage costs of goods. Additionally, industries such as special machinery offer individualized machines and therefore have small batch sizes even for serial parts. 3D printing allows on-demand production without minimum order quantities. This reduces the load on the warehouses and creates budget for other uses. If, in addition, supply chains and thus throughput times can be shortened, enormous economic as well as ecological potential can be realized.
Speaker/s
Jochen Loock DB Schenker Sales Manager
Jochen Loock is Business Development Manager at DB Schenker where he has the mission to grow a digital warehouse. With an entrepreneurial mindset he is connecting additive manufacturing to the spare parts business to create value for his customers.
Before, he worked as the head of additive academy, consultant and business development manager at the Fraunhofer IAPT to transfer AM innovation to the industry.
Fraunhofer Competence Field Additive Manufacturing
Opening new applications for LBM components with highly productive and cost-effective L-PBF process chains
Dr. Philipp Imgrund // IAPT
de
Fraunhofer Competence Field Additive Manufacturing
To open up new applications in the laser beam melting process (L-PBF), it is necessary to reduce costs along the process chain and to increase productivity and sustainability. In this sense, Fraunhofer IAPT has investigated the increase of layer thicknesses up to 150 µm, use of laser systems up to 1kW and the potential of beam shaping in an industrial L-PBF facility. It was shown that productivity can be increased by more than a factor of 3 compared to conventional L-PBF processes and costs can be reduced by more than 40 %. Further potential for increasing the efficiency of the process chain lies on the material side in the use of coarser particle size distributions and on the post-processing side in the automation of support removal processes.
Speaker/s
Dr. Philipp Imgrund IAPT Head of AM Processes Department
Dr. Philipp Imgrund studied materials science at the Technical University of Clausthal. He received his PhD in production engineering from the University of Bremen in 2007. From 2002 to 2014, he worked at Fraunhofer IFAM as a project manager in the development of the metal injection molding process and later as head of the medical technology business unit. In 2014, he moved to the company OBE MIMPlus as R&D project manager, where he was responsible for material and process qualification. In 2017, he moved to Hamburg to Fraunhofer IAPT, where he is leading the AM Processes department with now 20 employees. The focus of the department is development of laser and sinter-based additive manufacturing processes for both metallic and polymer materials.
3D Printing Conference
Granulatbasierter 3D Druck für eine wirtschaftliche Herstellung von Bauteilen
Marcus Witt // 1A Technologies UG
de
3D Printing Conference
Das Hemmnis bei der Industrialisierung 3D-gedruckter Bauteile sind bisher die Druckzeit sowie Materialkosten. Mittels SEAM (Screw Extrusion Additive Manufacturing) lassen sich Bauteile aus Standardgranulaten herstellen wodurch Materialkosten im Vergleich zu Filament bis zu 30 fach günstiger sind und eine Austragsleistung von 8kg/ Stunde ermöglicht kurze Bauzeiten. Durch kurze Bauzeiten können selbst höhere Maschinenstundensätze problemlos in Kauf genommen werden und der 3D-Druck kann als Standalone oder als Ergänzungsverfahren zur Hybridanlage eingesetzt werden. Hierbei ist vor allem eine Nachrüstung alter Anlagentechnik als auch eine Erweiterung und damit Erhöhung des Nutzungsgrades neuer Anlagentechnik enorm interessant und umfasst ein riesiges Portfolio von Anwendungen und Branchen. Es wird vorgestellt, welche Anwendungen hiermit adressierbar sind und wie durch eine sogenannte SEAM-autark Lösung jede Steuerung und jede Kinematik zum 3D-Drucksystem aufgerüstet werden kann.
Speaker/s
Marcus Witt // 1A Technologies UG
10:30-11:00
Design
LIVE-STREAM (eng + de)
Designing for AM Solutions in Sporting Goods
Sebastian Hess // DQBD GmbH
de
Design
Additive manufacturing for many years has been an essential part in the design development process of DQBD GmbH. Especially when designing sport products AM provides a high control level throughout the design development process by printing out design mockups for decision taking, ergonomic and volume models to check the fit of shapes to the body. With todays` variety of AM solutions and rethinking design specifically for AM products can step up to a new level by integrating fully functional AM end components.
DQBD has been showcasing in the last 10 years a lot of visionary concepts that today become reality.
Speaker/s
Sebastian Hess DQBD GmbH
2021/2022: Showcase von SAM_Saddle additive manufactured
2020/2021: Close cooperation with Stratasys
2020: Foundation of the company SPEEDFAB GmbH as shareholder
2016: Collaboration between DQBD (Advanced Innovation Partner) and SPORTSGEAR Group, one of the world's largest shoe factory group
Since 2015: DQBD works for the world's leading brands and companies in their respective sports product areas
2015/2016: AM Milestone IV: Showcase of AM components in the footwear sector
2015: AM Milestone III: Showcase of a bicycle saddle with integrated AM components
2015: AM Milestone II: Showcase of a cycling helmet with integrated AM components
2014: AM Milestone I: Collaboration with AUTODESK, STRATASYS, BASF on the e-FLOATER, a vehicle for "last mile" solution
2014: Foundation of the design and development company DQBD GmbH in Schorndorf nearby Stuttgart.
2011: Introduction of additive manufacturing and installation of the AM Lab at Alpinestars.
2010-2014: Working for ALPINESTARS in Italy/USA as Senior Designer and responsible for Technical Personal Protection as well as head of the Advanced Innovation Lab
2007: Founding of the Hess Design Studio in Heidelberg with focus on sports protection
Studies at the Academy of Arts and Design in Offenbach to become a product and industrial designer with diploma
Software & Processes
End-2-End traceability in additive series production by use of digital triplets
Dr. Ulrich Jahnke // Additive Marking
de
Software & Processes
With the advancing industrialization of additive manufacturing processes, quality management must be strengthened in order to increase profitability. Continuous and reliable traceability of information and material flows is the key to reducing error rates and the basis for the continuous improvement process. Material properties of marked parts and components that are to be expected in series production can also be traceably assigned to the individual build job. Digital triplet reliably bundles all relevant quality information, e.g. on mechanical properties. With software support, this data can be aggregated in a quality control chart, enabling early detection of trends and appropriate process control.The unique and tamper-proof labeling of production accompanying samples and components is a fundamental requirement for further automation, secure linking to the blockchain and the vision of Industry 4.0.
Speaker/s
Dr. Ulrich Jahnke Additive Marking CEO
Dr. Ulrich Jahnke looks back on more than 12 years of experience in 3D printing and additive manufacturing processes. After his studies in engineering informatics, he conducted research at the University of Paderborn and the associated Direct Manufacturing Research Center (DMRC). His research has been focused on quality management, workflow optimization and the question of how product piracy can be avoided by use of additive manufacturing processes. In parallel, Ulrich Jahnke founded Additive Marking GmbH in 2018 together with two partners with the vision of marking all 3D-printed components directly in the manufacturing process in a machinereadable way, thus creating the basis for the factory of the future. Through its innovative technology, Additive Marking GmbH connects the digital world with the physical world and brings the so-called "digital identities" to "physical assets" as these are the enabler of qualitymanagement, automation and brand protection.
Fraunhofer Competence Field Additive Manufacturing
Simulation of a Laser Powder Bed Fusion process from raw material to mechanical properties
Bastien Dietemann // IWM
de
Fraunhofer Competence Field Additive Manufacturing
A laser powder bed fusion (LPBF) process is modelled completely. The Discrete Element Method is used for powder spreading simulations yielding realistic powder beds. Smoothed Particle Hydrodynamics simulations are then used to study the thermal-viscous flow in the melt pool considering laser energy absorption, radiation, heat transfer, melting and re-solidification, surface tension, Marangoni currents and vaporization pressure. The temperature field of the melt pool is coupled to a Cellular Automaton, which calculates the growth of dendritic grains and, thus, provides a prediction for the microstructure formed during solidification. This microstructure serves then as input for Crystal Plasticity Finite Element Analyses to qualitatively describe texture dependent mechanical properties.
Speaker/s
Bastien Dietemann IWM Particle-based process modeling Business Unit Manufacturing Processes
Ausbildung / Education Bachelor of Science: Bioingenieurwesen, TU Dortmund (2010-2014) Master of Science with Honours: Advanced Materials and Processes, FAU Erlangen-Nuremberg (2015-2017)
Currently working: Since 2018: PhD Student at Fraunhofer IWM
Current activities Process simulation for additive manufacturing.
11:00-11:30
Coffee Break
Coffee Break
Speaker/s
(Kopie 10)
3D Printing Conference
Automated AM Part Identification: the Best Entry Point for Additive Manufacturing
Stephan Kühr // 3YOURMIND GmbH
de
3D Printing Conference
Advances in AM are making it competitive in a much wider set of production scenarios. But for most companies, there are still some major hurdles to implementation: fiHow can I start without any in-house experts? fiWhat should I start producing to build up that expertise?fl Stephan Kühr, CEO of 3YOURMIND will present Agile PLM software and define why it is the most important fistarting pointfl for AM. The software tool provides a clear report of parts that will immediately capture the potential of AM and fuel a company™s growth into this new production method. For companies, identifying the 5-10% of parts that can be easily converted to 3D printing is critical to the direct adoption of AM for other part families and future designs. Whether you™re at the beginning of your AM journey or well into it, generating an AM suitability report of full part inventories is a huge step towards building business cases for getting into AM, gathering resources needed, or anticipating future AM needs. Stephan will show how various companies are using this reporting tool to make smarter AM production decisions and save large amounts of time that previously would have been spent in manual evaluation.
Speaker/s
Stephan Kühr // 3YOURMIND GmbH
11:30-12:00
Design
LIVE-STREAM (eng + de)
Products of the future Architecture
Agnieszka Blonska // Aga Blonska Design
de
Design
Additive Manufacturing has become a more critical procedure in the design process of the building. New software and technology allowed us to change the process of production and create rapid prototyping. How will Architects work with production companies and design Architectural products in the future? What is the new workflow and dialogue between AM companies and Designers, and what should change in this conversation?
Speaker/s
Agnieska Blonska Aga Blonska Design Architect / 3D print Designer
Experience 2022 - current / Computational Design Specialist at Arktura, Amsterdam Script tools / Digital fabrication / Design automation 2021 - 2022 / Design Intelligence Operator at Etcetera, Amsterdam Product development / Digital fabrication / Speculative 3d printing projects 2019 - 2020 / Project Architect / 3D Print Designer at Studio RAP, Rotterdam Design / Concept / Digital manufacturing 2016 - 2019 / Architect / 3D Print Designer at DUS Architects, Amsterdam Design / Concept / BIM-coordination 2015 - 2016 / Architect at Rafal Zmorka Studio, Warsaw Technical drawings / Consultation on construction site 2012 - 2015 / Architectural Assistant at PRC Architects, Warsaw Specifications / Detail drawing / Interior drawings / Technical Coordinations 2010 - 2011 / Architect & Co-Founder at 2RAM, Poznan Design / Concept / Exhibitions / Innovation design
Education 2006 - 2011 / Master of Science (MSc Eng Arch) Architecture / University of Arts, Poznan
Courses 2021 / Space Architecture & Design / The Swiss Institute for Disruptive Innovation, Zurich 2021 / Design for Robotics / GSS21 / IaaC / Barcelona
Software & Processes
COLD METAL FUSION - Metal 3D-printing for serial production
Christian Fischer // Headmade Materials GmbH
de
Software & Processes
The heart of the 3D-printing process Cold Metal Fusion is our feedstock. It was developed to fit seamlessly into an existing ecosystem of machines and processes, to achieve high green part stability and without having to accept any compromises in the metal part properties. The machine park can be combined according to the respective requirements or you can use your existing processes and equipment.
Speaker/s
Christian Fischer Headmade Materials GmbH Co-Founder and Managing Director
Co-Founder and Managing Director Headmade Materials GmbH 2020 – Present
Project Engineer for Additive Manufacturing SKZ – Das Kunststoff-Zentrum 2013 – 2020
Project Engineer / Process Development Kurz Kunststoffe GmbH 2010 – 2013
Education
2007 – 2010 Mechanical Engineering (DHBW)
2011 – 2013 Material Science (FAU Erlangen)
Fraunhofer Competence Field Additive Manufacturing
Scanning strategies: an enabler for filigree components on existing LPBF systems
Dipl.-Ing. Hannes Korn // IWU
de
Fraunhofer Competence Field Additive Manufacturing
In terms of cost and principle, the strength of the Laser Powder Bed Fusion (LPBF) process lies in the production of components with complex, filigree geometries. In practice, however, their manufacturing represents a major challenge in terms of quality and reproducibility. Furthermore, the use of the contour-hatch scanning strategy imposes unnecessary limits here in terms of productivity and minimum feature sizes. Using examples from "challenging geometries", adapted scanning strategies are presented that can reduce minimum feature sizes and improve reproducibility and part quality - while significantly increasing productivity. This enables the development of new applications on existing LPBF systems in a cost-effective manner.
Speaker/s
Dipl.-Ing. Hannes Korn IWU Research Associate
Mr. Korn successfully completed his mechanical engineering studies at TU Dresden in 2017 and has since been working as a research associate at Fraunhofer IWU on innovative application scenarios and the optimized manufacturing of filigree metallic structures on conventional LPBF system technology. His research focuses on the simultaneous increase of manufacturing quality and productivity through the development and application of geometry-specific exposure strategies. This complex of topics also forms the content-related foundation of his current doctoral thesis at the TU Chemnitz. In close cooperation with partners from the TU Dresden, he is contributing his experience from software development in the context of designing AM-specific software solutions for manufacturing data generation.
3D Printing Conference
Entwicklung von Anlagen zum Druck von Keramiken und Medizinklasse 3 Produkten
Mario Aubel and Raflf Röder // BURMS 3D Druck GmbH und Co.KG
de
3D Printing Conference
Thema 1: Entwicklung einer Anlage zum Druck von Keramiken
Ziel ist die Entwicklung von innovativen, thermisch leitfähigen Duro-plastharzen und die Entwicklung eines neuartigen 3D-Druckers zur Fertigung von Formeinsätzen für die Verwendung im Spritzgussprozess. Überwiegend werden diese Einsätze aus Metallen gefertigt und kosten zwischen 5.000€ bis 40.000€ pro Formeinsatz. Durch die hohen Kosten ist das Abformen im Prototypenmaßstab nicht wirtschaftlich. Durch dieses Projekt sollen möglichst günstige Formeinsätze für das Spritzgussverfahren entwickelt und gebaut werden. Hierfür sollen thermisch leitfähige Keramik-Harzsysteme produziert werden. Durch die schlechte Verarbeitung dieser Harze muss eine Maschine zum Verarbeiten von hochviskosen Pasten entwickelt werden.
Thema 2: Entwicklung einer Anlage zum Druck von Medizinklasse 3 Produkten
Ziel ist die Herstellung von Medizinklasse 3 Produkten nach MDR mittels eines 3D-Druckers, welcher innerhalb einer Reinraumumgebung arbeitet. Dabei erfolgt der Druck, Reinigung und Nachbelichtung vollautomatisiert, und unter Einhaltung aller Anforderungen an Dokumentation und Protokollierung.
Speaker/s
Mario Aubel and Raflf Röder // BURMS 3D Druck GmbH und Co.KG
12:00-12:30
Design
LIVE-STREAM (eng + de)
Design and Additive Manufacturing - Evolution and Future Trends
Michail Desyllas // Al Build Limited
de
Design
Michail Desyllas was Design Lead at Zaha Hadid for eight years and now Co-Founder and Chief Operating Officer at Ai Build, a London based 3D printing software technology company.
An expert in Parametric Design, Digital Fabrication and 3D Printing, join Michail as he shares his experience from experimenting with design concepts and methodologies and how these were incorporated into global projects including The Henderson Tower, The Grand Théatre Rabat, and The International Exhibition Centre.
In that journey Michail has built a deep understanding of the opportunity that linking design strategy and large scale 3D printing presents, as well as the obstacles that would need to be addressed to enable this revolutionary technology to become mainstream.
Michail will present how he applied his design DNA to technology innovation, describe the current state, the future trends and the opportunities that this will present globally
Speaker/s
Michail Desyllas Al Build Limited Chief Operating Officer
Michail trained as an Architect having studied at the Architectural Association DRL, where he gained his MArch in Advanced Algorithmic Geometries.
Michail is an expert in Parametric Design, Digital Fabrication and 3D Printing and joined Zaha Hadid in 2012, working as Lead Designer and Project Associate on major global projects including The Henderson Tower (China), The Grand Théatre Rabat (Morocco) and The International Exhibition Centre (China).
After eight years with Zaha Hadid Architects and recognising the potential that 3D printing could provide, in 2020 Michail became the Co-Founder and Chief Operating Officer of Ai Build, a London based 3D Printing software company.
Ai Build’s software platform fully automates the Additive Manufacturing process and enables large format 3D printing to scale through automation, across applications and materials.
Software & Processes
From material development to (eco-) efficient product / tool
Dr. Christian Lindemann and Florian Hengsbach // DMRC - Uni Paderborn
de
Software & Processes
The lecture will focus on the role of "new" materials for additive manufacturing. These play a decisive role in the field of tension between product and process design. They often make innovative product design possible in the first place. It will be shown how materials and dedicated material design can drive the design of (eco-) efficient products. In this context, three different case studies (e.g. tooling) will be presented and discussed. The lecture concludes with an outlook on future products through new materials.
Speaker/s
Dr. Christian-Friedrich LindemannFlorian Hengsbach
Dr. Christian-Friedrich Lindemann Direct Manufacturing Resarch Center - Paderborn University Managing Director
Dr Christian Lindemann is the Managing Director of the Direct Manufacturing Research Center (DMRC) at the University of Paderborn. He has worked here since 2010, first as a research assistant and then as a "Research & Exploitation Manager". Mr Lindemann wrote his doctorate on the topic of "cost-effective design and planning with additive manufacturing processes". His research pursues the overarching goal of advancing the industrialisation of additive manufacturing processes and especially simplifying their implementation in companies.
Florian Hengsbach Direct Manufacturing Resarch Center - Paderborn University Ph. D. candidate
Florian Hengsbach is a Ph.D. candidate employed by Chair of Materials Science at the Paderborn University and works at the "Direct Manufacturing Research Center" (DMRC). Since 2015, he has been working on process and material development in the field of metallic, laser-based additive manufacturing.
Fraunhofer Competence Field Additive Manufacturing
Product Protection in Additive Manufacturing
Julian Ulrich Weber // IAPT
de
Fraunhofer Competence Field Additive Manufacturing
Clear and reliable component markings are a common means of protecting against product piracy, especially when they are volume-integrated into components and are therefore not visible from the outside. Additive manufacturing offers the possibility to integrate such volume-integrated component markings directly into the resulting components without significant additional effort. Fraunhofer IAPT has developed a process chain with an associated scanning system for component identification to reliably track such components. The mobile hand-held scanner works wirelessly and transmits corresponding component data wirelessly into the data system.
Working student, Fraunhofer IAPT, Hamburg — 01/2018 - 04/2019
Research assistant, Laser Zentrum Nord GmbH, Hamburg — 04/2015 - 12/2017
Education
Hamburg University of Technology (TUHH) — M.Sc. 10/2012 - 04/2019
- M.Sc. Mechanical Engineering and Management (Final grade 1,5) - Focus: Production Technology, Product Development and Business Development - Bachelor thesis: Optimization of a Laser Metal Deposition process for the economical manufacture of Ti-6AL-4V structures - Master thesis: Agile methods for the development of an opto-electrical sensor system
3D Printing Conference
How To Innovate: Design for indirect AM
Mike Schimmelpfennig // MetShape GmbH
de
3D Printing Conference
Indirect Additive Manufacturing provides a variety of different processes. From CMF to LMM to Binder Jetting. The challenge of all of these: Warping during sintering. To avoid the warping, parts should be designed properly and supported through sinter supports. The lecture will provide tips & tricks with real cases.
Speaker/s
Mike Schimmelpfennig // MetShape GmbH
12:30-13:00
Design
LIVE-STREAM (eng + de)
Networking of digital processes and creativity. How RP stimulates the thinking process
Alexander Christ // DDS
de
Design
Networking digital processes and creativity. How modern rapid prototyping processes can trigger new thought processes for the production and implementation of innovative products. People often think that rapid prototyping only makes sense once they have s ufficiently thought through and designed a product or parts of a product. But when you hold the part in your hands, you think of hundreds of things you could have done better with the product or part of the product. These are sudden thoughts that everyone has had when building or printing something. In future development processes, creative, design and manufacturing processes will be directly and synchronously linked. Creative processes will happen in the interaction "human machine" and for the first ti me "machine human" and thereby new approaches strategies, as well as new innovations will emerge. But what happens in our brain when divergent thinking, i.e. unsystematic and experimental thinking without precision, meets mathematically controlled proce sses with the highest precision? Using examples, I will show you that this process will significantly change the development of products in the future.
Speaker/s
Alexander Christ DDS
Alexander Christ was born 28.06.1969 in Cologne. After school craft apprenticeship as a carpenter. Studied at the "bergische Universität BUGH Wuppertal" to become a certified industrial designer. Since 1996 working as a designer in different development offices and in the industry like the Mercedes Benz Group Since 22 years self-employed with the development and consulting company DDS Digital Design Solutions.
Software & Processes
Oqton – an Intelligent Manufacturing OS
Benedikt Ebner // Oqton Inc. – Additive Manufacturing Software
de
Software & Processes
In this session we will share our vision on how you can increase innovation and efficiency by intelligently automating your end-to-end additive manufacturing process. With smart manufacturing limited by gaps between disconnected design and production platforms, manufacturers are forced to rely on many different skills and people. That’s why we need a technology agnostic, AI-powered Manufacturing OS that unifies engineering and production through IoT and machine learning to solve manufacturing challenges across industries. Listen in and join the discussion!
For more than 6 years, Benedikt Ebner has been working in different companies in the field of additive manufacturing and has become an expert in this area. In his current position as Sales Executive EMEA at Oqton Inc., he pursues the overall goal of automating additive manufacturing and the associated processes more strongly and transferring them into the digital world with the use of the AI-powered Manufacturing OS from Oqton. Benedikt Ebner completed his studies in Product Engineering (B.Sc.) at Furtwangen University in 2012. This was followed in 2015 by a degree in Innovation Management (M.Sc.) at the University of Applied Sciences Ludwigshafen am Rhein.
Fraunhofer Competence Field Additive Manufacturing
Technological qualification of the LPBF within the pharmaceutical and food industries
Dipl. Ing (FH) Sebastian Stelzer // IWU
de
Fraunhofer Competence Field Additive Manufacturing
In hygiene-critical industries such as the food and pharmaceutical sectors, particularly high demands are required on the design of the components used, especially in contact areas with the product. This results in high effort and consequently high costs in manufacturing with conventional processes, since many processing steps are necessary to produce complex individual components. In reality, therefore, hygienic design is often compromised in favor of more cost-effective production, which has a negative impact on food safety. However, the production of components by LPBF in hygienic design does not increase the production effort. Compromises that have a negative impact on food safety, e.g. the connection of several assemblies via weld seams, can be avoided in this way. This stands in contrast to the guideline values of average roughness values (Ra 0.8 µm), which are important for cleanability in the context of the pharmaceutical and food industries, but which cannot be implemented by LPBF. Within the presented work, the requirements of the industry are presented and different post-processing methods for internal channels, produced by LPBF, are compared. Further on, possible strategies for surface improvement are explained.
Speaker/s
Dipl. Ing (FH) Sebastian Stelzer IWU Research Associate Department Laser Powder Bed Fusion
Since 2009, Mr. Stelzer has been involved in the application of laser technology in production. After research and development on the application of the LPBF process in an industrial environment, he has been working at Fraunhofer IWU within the Laser Powder Bed Fusion department since 2016. His experience covers a very broad spectrum. In the past, the focus was on the optimization of actively cooled additively manufactured gear components and on process development for hybrid additive manufacturing of metallic structures on ceramic substrates. Currently, he is significantly involved in modern processes to improve the quality of additively manufactured surfaces for use in industry. In the context of this topic, he is incorporating his experience from the industrial environment into several ongoing projects with partners from industry.
3D Printing Conference
Taking 3D Printing of Flexible Material from Prototyping to Industrial Manufacturing
Dr. Bart Engendahl // Chromatic 3D Materials GmbH
de
3D Printing Conference
Chromatic 3D Materials stellt flexible, funktionale und wirtschaftliche Bauteile mittels der patentierten reaktiven Flüssigdeposition, Reactive Liquid Additive Manufacturing (RLAM) her. Zwei Flüssigkeiten werden durch eine Mischdüse gepumpt, in der eine chemische Reaktion ein dauerhaft quervernetztes Polyurethan herstellt. Das glatte, nicht poröse Polyurethanelastomer ist verwendbar für Bauteile wie beispielsweise Formteile und Dichtungen, Federbälge, Tüllen und Kappen in Mobility Bereich, im Land- und Industriemaschinenbau, in der Medizintechnik und weiteren Anwendungsgebieten. Hybride Bauteile sind herstellbar durch die gute Anhaftung des Polyurethans an Metal, Kunststoffen und Textilien. Im Gegensatz zu den meisten anderen 3D-gedruckten Materialien sticht Chromatic’s Technologie durch Langzeitstabilität in einem Temperaturbereich von -40°C bis 150°C hervor und ist resistent gegen hohe Drücke und Chemikalien. Bei einer Shore Härte von A 40 bis A 90 werden Zugfestigkeiten von 4.5 MPa to 18 MPa erreicht. Reißdehnungen von bis zu 550% und einen niedrigen Druckverformungsrest. Die mit diesem Verfahren hergestellten Teile sind Polyurethan Elastomere, die in vielen Fällen auch GummiElastomere ersetzten können. Wir werden die Vorzüge und Limitationen des Verfahrens anhand eines Mud-Guards für eine Landwirtschaftliche Maschine vorstellen. Dabei handelt es sich um ein großes Bauteil für das Druckgeschwindigkeiten von kg/hr erreicht werden. Das Bauteil musste eine profilierte Oberfläche haben und dufte keine thermischen Spannungen Enthalten.
Speaker/s
Dr. Bart Engendahl // Chromatic 3D Materials GmbH
13:00-14:00
Lunch Break
Lunch Break
Speaker/s
14:00-14:30
Keynote: Sustainability in mass production of consumer goods using AM technologies for hybrid concepts and repairs
LIVE-STREAM (eng + de)
Klaus Eimann // Procter & Gamble
de
Keynote: Sustainability in mass production of consumer goods using AM technologies for hybrid concepts and repairs
Today, anyone who wants to manufacture mass products with high-tech production equipment must always reckon with a finite service life and the failure of significant machine components. As early as the project planning stage of a production machine, the designer must make compromises in terms of material technology while keeping an eye on the service life and robustness of the components. With laser DED (Direct Energy Deposition), a process is available that allows the workpiece and later machine component to be optimally adapted to the production conditions.
The characteristics and functionality of the component thus correspond almost completely to the process requirements. The functionality of the surface in terms of hardness and corrosion resistance can be decoupled from the rest of the component without losing focus on the manufacturing and maintenance costs. The latter can be significantly reduced, while at the same time saving resources in terms of material, time and money.
Speaker/s
Klaus Eimann Procter & Gamble Service GmbH Technical Director Product and Packaging Innovation
Braun AG, Professional training tool maker, Specialisation mold making, degree in mechanics and plastics engineering
Braun GmbH, Leader tool shop subject maintenance and repair,
Procter & Gamble manufacturing / service GmbH, Technical section head laser machining and additive manufacturing
Procter & Gamble manufacturing / service GmbH Technical director product and packaging innovation
3D Printing Conference
Differentiating by competence with open laser sintering systems
Dr. Dirk Simon // Farsoon Europe GmbH
de
3D Printing Conference
Lasersintern ist das am meisten industriell genutzte Verfahren in der Additiven Fertigung. Zunehmend werden dabei spezielle Eigenschaften der Bauteile gefordert. Dies wird durch den Einsatz diverser Materialien möglich gemacht, jedoch braucht es detaillierte Prozesserfahrung. Bei offenen Systemen kann der Anwender viele verschiedene Pulvermaterialien einsetzen und die Prozessparameter frei einstellen. Mit der Optimierung auf die geforderten Eigenschaften entwickelt sich eine proprietäre Kompetenz, mit der sich die Bauteilhersteller differenzieren können. Der Vortrag wird die Vielfalt der Pulvermaterialwahl und die Einflüsse von Prozessparametern auf zeigen.
Speaker/s
Dr. Dirk Simon // Farsoon Europe GmbH
14:30-15:00
Tool-, Model- & Mould Making
LIVE-STREAM (eng + de)
3D printing in model and mould making – yesterday, today and tomorrow
Johannes Zech // Bundesverband Modell- und Formenbau
de
Tool-, Model- & Mould Making
At the beginning of the 1990s, when stereolithography, one of the oldest additive processes for the production of three-dimensional objects, enabled its first applications in model and mould making, few people knew how important 3D printing would become for the industry. In conversation with Johannes Zech, President of the German Association of Model and Mould Making (BVMF), these developments are to be followed and the future is to be looked at.
Speaker/s
Johannes Zech Bundesverband Modell- und Formenbau
Born on 10. 12. 1967
Start of vocational training to become a foundry model maker 01. 08. 1983
Examination of journeymen in the model-making trade 31. 01. 1987
Master’s examination in the modelling trade 23. 03. 1993
Founding of Zech und Waibel Modellbau GbR 01. 04. 1998
Stellv. Master of the Model Maker Guild Düsseldorf Nov. 2012
Master of the Model Maker Guild Düsseldorf Nov. 2015
Chairman of the Vocational Training Committee
Federal Association of Model and Mould Making May 2016 to April 2021
President of the Federal Association of Model and Mould Making e. V. April 2021
AM in Construction Engineering & Architecture
Additive manufacturing with shotcrete
Prof. Norman Hack // Universität Braunschweig
de
AM in Construction Engineering & Architecture
The building industry is one of the least digitalized sectors of the global economy to date. Unlike other industrial sectors, the manufacturing of buildings is characterized by traditional handicraft techniques and individualized construction processes. Digital production technologies from other industrial sectors have not become established in the construction industry because they do not allow the necessary individualization or are uneconomical to transfer to construction. The advantages of additive manufacturing (AM) technologies are that automation and individualization are not contradictory. Furthermore, a new design strategy is embedded in 3D printing, namely to build up material only where it is structurally or functionally needed. AM is, therefore, both economical and resource-efficient. In his presentation Norman Hack will highlight the recent research findings of the Institute of Structural Design (ITE) with regards to Additive Manufacturing on the large scale of construction. A particular focus will be directed towards the so-called Shotcrete 3D Printing Technology which was developed by TU Braunschweig in recent years.
Speaker/s
Prof. Norman Hack Universität Braunschweig
Norman Hack is an architect and researcher in the domain of computational architectural design and digital fabrication. He holds a degree in architecture with distinction from Vienna University of Technology and a master's degree with distinction from the Architectural Association in London. After completing his studies, he worked as a coding architect in the Digital Technologies Group at Herzog & de Meuron on projects at various scales and planning stages, from conceptual design to construction planning and from furniture scale to urban design. His interest in integrative digital design and fabrication processes led him to pursue a PhD with Gramazio Kohler Research, which he began at the Singapore-ETH Centre (Future Cities Laboratory) and completed at the National Centre of Competence in Research in Digital Fabrication at ETH Zurich. Among other recognitions, his research has been awarded with the Swiss Technology Award and the ETH Medal for outstanding doctoral theses. From 2018 until 2021 Norman held a tenure track professorship for Digital Building Fabrication at the Institute of Structural Design (ITE) at Technische Universität Braunschweig. At the beginning of 2022 he was appointed full professor in Digital Construction at the same institute. Norman is a member of the executive board of the newly founded Collaborative Research Centre "Additive Manufacturing in Construction" and spokesman of the research area "Design and Construction".
Fraunhofer Competence Field Additive Manufacturing
Use Case Recycling Industry: Cutting Crowns
Dr. Burghardt Klöden // IFAM
de
Fraunhofer Competence Field Additive Manufacturing
Electron beam melting is an additive manufacturing technology in which components are manufactured layer by layer by melting them in a powder bed using an electron beam. Material and component options arise from the properties of the process and the raw material. The presentation will begin with the state of the art, which will include an introduction to the technology and materials that are available today. In the second part, a use case from the recycling industry will be presented. Results on the material (FeCr-10V) regarding processability and properties will be presented. Furthermore, results on demonstrators (cutting tool) are presented with regard to their fabrication and testing under real conditions.
Speaker/s
Dr. Burghardt Klöden IFAM
Burghardt Klöden graduated as »Dipl.-Phys.« in physics from Dresden University of Technology, Germany, and University of Sheffield, UK, in 2002. In 2006, Burghardt obtained his »Dr. rer. nat.« (PhD) degree from TU Dresden, Faculty of Natural Sciences. He has joined the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM as a scientific researcher in 2006, where he helped establishing »Additive Manufacturing by Electron Beam Melting« as a new field of research and has been managing this as the responsible Group Manager since 2016.
Burghardt has recurrently worked with additive manufacturing / 3D printing technologies for more than 9 years, focussing now on electron beam melting technology (PBF-EB) and aspects of powder for additive manufacturing. Burghardt has authored 30+ technical and scientific publications and presented also 40+ technical papers at national and international conferences, symposia and workshops.
3D Printing Conference
3D-Printing-Workflow as Single Source Solution
Miriam Irie // Mimaki Deutschland GmbH
de
3D Printing Conference
3D-Druck geht nicht erst beim Druck los und hört auch nicht damit auf. Sind die Daten fehlerfrei und zum Drucken geeignet und wie entferne ich das Stützmaterial am besten? Mimaki bietet für all diese Schritte Lösungen an, wie diese aussehen, erfahren Sie hier.
Speaker/s
Miriam Irie // Mimaki Deutschland GmbH
15:00-15:30
Tool-, Model- & Mould Making
LIVE-STREAM (eng + de)
How does AM fit in with new business models
Werner Stapela // Danfoss
de
Tool-, Model- & Mould Making
Introduction to Danfoss, overview of how 3DP/AM fits into the picture, followed by the 3DP/AM journey in general industry to date, including the attempt to transform from prototyping >> end component manufacturing. What hurdles exist for the above transformation, how to execute adoption at an industrial company (Danfoss as example). Going forward, what strategic imperatives and business models lie ahead for 3DP/AM, how will they accommodate adoption. Finally, Q&A.
Speaker/s
Werner Stapela Danfoss
Experienced manufacturing industry manager. Additive Manufacturing and 3D Print expert, with implementation strategy and implementation of AM in industry as a sweet spot. Extensive operational experience as a general manager of companies and groups of companies, primarily in B-B and with a dominance in packaging and additive manufacturing/3D printing. M&A experience both as a buyer with P+L responsibility representing a consortium, and as an intermediary for an M&A boutique.
AM in Construction Engineering & Architecture
Combination of additive technologies for prefabricated concrete construction
Prof. Dr.-Ing. habil. Sandra Gelbrich and Enrico Rudolph // Technische Universität Chemnitz
de
AM in Construction Engineering & Architecture
Additive technologies for the production of precast concrete parts are predestined to become key technologies in the construction industry. In particular, the flexibility of design in combination with the highest precision and a high degree of automation are important advantages compared to well-known, less automated processes, such as concrete casting technology. However, in the case of production by concrete extrusion (concrete 3D printing), the process-related layer-by-layer surface structuring of the finished concrete parts often hinders a broader application. Combining additive concrete extrusion with conventional manufacturing processes (e. g. concrete casting and spraying) allows the respective advantages of the technologies to be exploited in a targeted manner for the efficient production of lightweight precast concrete parts with a high surface quality. Within the framework of current research, two new additive processes are being investigated at the TU Chemnitz: Injection extrusion and casting extrusion, are being investigated in terms of materials and technology and validated using demonstrators. Injection extrusion is especially suitable for wall elements and façade solutions.
The combination of a thin shotcrete layer and an extruded reinforcing structure with integrated load transmission elements allows the production of resource-efficient elements, that have high-quality surfaces in addition to the required load-bearing capacities. The developed combined spraying-extrusion nozzle allows adapted mortars and concretes to be both: sprayed and extruded. The casting-extrusion process has enormous potential for formwork-free construction methods, which can be used for the production of stairs, for example. For this purpose, the formwork is extruded as a lost mould and then the required reinforcement elements are integrated before the final casting process takes place. In order to ensure the demanded composite properties and surface qualities, an exact and defined formation of the formwork edges and surfaces must be ensured on the production side.
Speaker/s
Prof. Dr.-Ing. habil. Sandra Gelbrich Head of research division "Lightweight construction " Technische Universität Chemnitz
1995-2001 Study of civil engineering at the Bauhaus University Weimar
2002-2007 Scientific assistant at the TU Chemnitz
2008 Doctorate
Since 2009 head of the research group LBW
2016 Habilitation
2019 Sächsischer Staatspreis für Baukultur
2020 Appointment as professor
Enrico Rudolph Research Associate Technische Universität Chemnitz
2006-2007 Study of mechanical engineering at the Technische Universität Ilmenau (B: Eng.)
2007-2009 Study of mechanical engineering at the University of Applied Sciences Mittweida (B. Eng.)
2009-2012 Study of mechanical engineering at the University of Applied Sciences Mittweida (M. Eng.)
Since 2012 Research assistant at the University of Technology Chemnitz
Since 2020 Head of the working group Additive Lightweight Construction Technologies in Civil Engineering
Fraunhofer Competence Field Additive Manufacturing
Increasing the efficiency of mobility concepts through LPBF
Simon Vervoort // ILT
de
Fraunhofer Competence Field Additive Manufacturing
The transformation to carbon free traffic and transportation requires technological solutions for the mobility of the future. Depending on desired range and performance, zero-emission combustion engines can be superior to purely electric drive concepts. The presented project displays the production of an engine (crankcase, cylinder head, bedplate) using additive manufacturing and hybrid construction with high-performance polymers. The LPBF process (laser powder bed fusion) used enables consistent lightweight construction, improved cooling, flow-optimization, and local thermal insulation. The measures increase the efficiency of the engine and aim at enabling the future use of green hydrogen in according combustion engines.
Speaker/s
Simon Vervoort ILT
Simon Vervoort, Dipl.-Ing., group manager ‘Application Development LPBF’, received his graduate degree in mechanical engineering (Jet Propulsion and Turbomachinery) from RWTH Aachen University. After working at Siemens Winergy in Elgin, IL, he started pursuing his PhD in the field of laser powder bed fusion at Fraunhofer Institute for Laser Technology in 2014. His work is focused on the integration of sensors and electronics into LPBF parts.
3D Printing Conference
Making the voice of additive manufacturing heard in politics
Dr. Justus Bobke // Verband 3DDruck e.V.
de
3D Printing Conference
Fakt: Schon heute können Häuser oder Teile von diesen, Konsum- und Gebrauchsgüter aber auch Herzen, Implantate, Steaks, Fahrräder, Ersatzteile und Kleinserien gedruckt werden. Der Fortschritt ist Jahr für Jahr auf der Messe rapid.tech zu bestaunen. Fragen: Hat die Politik verstanden, dass sich Produktionsprozesse radikal ändern können? Verändert die Additive Fertigung das Axiom, das ein Konstrukteur den Herstellungsprozess bestimmt? Gelingt es bei zunehmenden Individualisierung die Produktion von Einzelteilen zu Serienstückkosten zu erzielen? Welche Chancen bietet der 3DDruck für nachhaltige Wettbewerbsfähigkeit in Deutschland und Europa? Das sind nur einige ebenso hochinteressante wie relevante Fragen. Vor allem: Wie verschafft man sich in der Politik Gehör? Vorgehen: Der Verband 3DDruck e.V. verfolgt seit seiner Gründung 2016 einen branchenübergreifenden und umfassenden Ansatz als überparteiliche Denkfabrik. Wir bilden strategische Allianzen mit allen Stakeholdern, die sich für die Entwicklung der Additiven Fertigung befassen und tragen gemeinsam erarbeitete Ideen und Impulse in die Politik. Es ist unser Ansporn, im Interesse unserer Mitglieder und Partner der Politik vorausschauende, konkrete und hilfreiche Impulse zu geben. Wie wir es machen, zeigt Ihnen der Vortrag auf der 3D Printing Conference anlässlich der rapid.tech 3D 2022.
Speaker/s
Dr. Justus Bobke // Verband 3DDruck e.V.
15:30-16:00
Coffee Break
Coffee Break
Speaker/s
(Kopie 6)
3D Printing Conference
Large scale Metal AM with Hybrid WAAM
Paul Diers // MX3D
de
3D Printing Conference
Um die Ausfallzeiten und Betriebskosten zu minimieren, halten beispielsweise Betreiber von Energieanlagen große Lagerbestände hochindividueller Bautelie vor. Hierfür hilft Robotic Wire Arc Additive Manufacturing dabei, Lagerbestände zu minimieren und eine Produktion von Ersatzteilen vor Ort ermöglicht. MX3D´s Fallbeispiel eines gebogenen Verbindungsrohrs (WAAM Clamp), welches sich zu den Nominierten der 3D Pioneers Challenge zählen darf, zeigt eindrucksvoll, wie Vorlaufzeiten reduziert werden, eine automatisierte Produktion funktionieren kann sowie der Materialbedarf drastisch zu reduzieren ist.
Speaker/s
Paul Diers // MX3D
16:00-16:30
Tool-, Model- & Mould Making
LIVE-STREAM (eng + de)
Printed Tooling - Applications & Road to Serial Production
Tobias King // Voxeljet
de
Tool-, Model- & Mould Making
In addition to the production of functional components, 3D printing of tools and molds offers an optimal opportunity for the production of components, depending on the desired materials, required quantities, etc. The advantage: For the user, this means working with certified processes with known materials and properties. The charming thing for the user is that tool-less molds can be created within days instead of weeks and at a fraction of the cost. The presentation will highlight possible applications of additively printed tools and molds for use in metal casting, thermoforming, laminating or, for example, concrete formwork construction. In addition, requirements and post-treatment options for 3D-printed molds will be highlighted. The materials used are quartz sands selectively bonded via binder jetting of resins on an industrial scale up to 8 m³ at a time. In addition, the presentation will provide an insight into a first project that has succeeded in establishing binder jetting in series production as well as its requirements for the entire workflow in order to significantly increase output quantities.
Speaker/s
Tobias King voxeljet AG Director Marketing & Application
Tobias King joined voxeljet as project engineer in system assembly and after sales in 2008. Later he assumed responsibility for the Sales and Marketing department where he contributed to expand voxeljet´s global partner network, increasing sales and brand awareness. This lead to further expansion of the service of on-demand part production as well as system sales. Since 2014 he has served as Director Marketing & Applications focusing on communication, PR as well as new markets, gathering information on new additive manufacturing applications.
AM in Construction Engineering & Architecture
Additive manufactured load-bearing components made of mineral building materials - Verification of
usability in the view of technical building regulations
Prof. Thorsten Stengel // Ingenieurbüro Schießl
de
AM in Construction Engineering & Architecture
This article reports on the first 3D-printed buildings realized in Germany and highlights all aspects with regard to the currently existing building regulations. In addition, the concept for the verification of usability is explained, the building material and component tests carried out are discussed and the main test results are briefly summarized. The presentation concludes with a short report on the progress of 3D printing during execution and an outlook on currently ongoing research work at Munich University of Applied Sciences.
Speaker/s
Prof. Thorsten Stengel Ingenieurbüro Schießl
10.1997 – 12.2002 Civil engineering study at Technical University of Munich
02.2003 – 01.2006 Research assistant at chair of building materials at Technical University of Munich (Prof. Peter Schießl)
01.2006 – 09.2008 Head of working group concrete technology at chair of building materials at Technical University of Munich (Prof. Peter Schießl / Prof. Christoph Gehlen)
12.2013 phD-thesis on bond of steel fibres in UHPC
02.2010 – 12.2016 Consultant at Schiessl Gehlen Sodeikat consulting company
01.2017 – 07.2020 Partner and manager of Schiessl Gehlen Sodeikat consulting company
03.2020 Professorship at MUAS: Full professor for construction chemicals and building materials at Munich University of Applied Sciences
Main fields of research
UHPC and fibre reinforcement for UHPC
High-performance mineral based building materials
Durability of concretes used for infrastructure projects
Material performance based design and test methods (see second fib paper!)
New (CO2-reduced) binders and SCM‘s
Sustainability and life cycle assessment of concrete structures
Thermal cracking in massive structures
Application of 3D printing techniques in civil engineering structures
AM in User Practice
Use of additive manufacturing in machine tools
Friedemann Lell // DMG MORI Additive GmbH
de
AM in User Practice
The machine tool business is said to be very conservative and mainly uses components, which are designed for stability and durability. Light weight designs and special materials like Titanium or Inconel are rare exceptions.
If the advantages of additive manufacturing and the related design guidelines are considered during the design phase of a machine, components can be identified, for which additive manufacturing offers advantages like shorter production time, cost reduction, integration of functions and even improved accuracy. Various additively manufactured components are shown as examples, which have found their way into the series production of machine tools due to these advantages.
Speaker/s
Friedemann Lell DMG MORI Additive GmbH Managing Director
Managing Director DMG MORI Additive GmbH Since 6/2021 Sales, Marketing, Controlling, Application Successor of the REALIZER GmbH, LPBF machines for all applications
Managing Director EMAG Salach GmbH From 1/2017 until 5/2021 Sales responsibility for EMEA and ex GUS, Production Modular Standard Machines, Service, Training. Production solutions for large series manufacturing, mainly for automotive industry
Sales Director SAUER LASERTEC, DMG MORI AG From 10/99 until 12/2016 Sales Director for laser technologies including laser ablation, cutting, drilling, additive manufacturing DED technology. Responsibility for application and product management.
Sales and Marketing Director Machines at Walter AG, Tübingen From 1/97 until 9/99 Responsible for sales service and marketing of CNC tool grinding machines
16:30-17:00
Tool-, Model- & Mould Making
LIVE-STREAM (eng + de)
How to optimize your tooling workflow for manufacturing with Additive Manufacturing?
Tom Neumann // 4D Concepts GmbH
de
Tool-, Model- & Mould Making
Tools used in manufacturing of parts refer to anything that needs to be implemented in order to produce a part. Tools are sometimes even a crucial determinant of the end-quality and geometry of the final product.
But in what way can additive manufacturing revolutionize the current processes? While many types of AM technologies exist, Fused Filament Fabrication (FFF) technology brings a rapid, efficient way to replace metal parts via 3D printing high-performance plastics.
What kind of possibilities would this bring?
3D printing allows a freedom of design to obtain the perfect fitted tool while High-Performance Polymers - through their mechanical properties - allow a usage of the tool even in complex environments.
Find out more through the presentation of Tom Neumann, Service | Support and Application Expert FFF at 4D Concepts.
Speaker/s
Tom Neumann 4D Concepts GmbH
Additive Experiences: • „Additively grown up“ (Father Dipl.-Ing. Rainer Neumann founded 4D Concepts GmbH in 1995) • Since 2019, 3D-Systems certified service engineer for MultiJet Printing systems as well as ProJet X60 systems • Since 2019, Markforged certified service engineer for composite systems • Works at 4D Concepts in service and support as well as application engineer for the FFF systems during his study program
AM in Construction Engineering & Architecture
Eco-Parametric Architecture.
Arthur Mamou Mani // Mamou Mani Architects
de
AM in Construction Engineering & Architecture
According to the UN Environment and the International Energy Agency', our building industry is responsible for 39% of all carbon emission. Architects, engineers, contractors and everyone else involved in our field now have a duty to work collectively to reduce our carbon impact. The environmental cost has to take priority over financial values and our materials and design technologies need to serve this higher purpose. Arthur Mamou-Mani is an architect specialised in eco-parametricism, looking at coupling a cradle to cradle approach to design with the maker's movement. Through several of his practice's projects, Arthur will show how parametric design can bring us closer to the natural world.
Speaker/s
Arthur Mamou Mani Mamou Mani Architects
Arthur Mamou-Mani is a French architect and director of the award-winning practice Mamou-Mani Architects, which specialises in a new kind of digitally designed and fabricated architecture. He is a lecturer at the University of Westminster and owns a digital fabrication laboratory called the FabPub which allows people to experiment with large 3D Printers and Laser Cutters. Since 2016, he is a fellow of The Royal Society for the Encouragement of Arts, Manufactures and Commerce. He has won the Gold Prize at the American Architecture Prize for the Wooden Wave project installed at BuroHappold Engineering. Arthur gave numerous talks including the TedX conference in the USA and has been featured in The New-York Times and Forbes. Mamou-Mani’s clients include ARUP, Buro Happold Engineering, Karen Millen Fashion, The Burning Man Festival, Food Ink and Imagination ltd. Prior to founding Mamou-Mani in 2011, he worked with Atelier Jean Nouvel, Zaha Hadid Architects and Proctor and Matthews Architects.
AM in User Practice
Geometric complexity as key factor for competitiveness
Tobias Häfele // htw Saar
de
AM in User Practice
Additive Manufacturing is characterized by freedom of design, which is less restricted compared to conventional processes, so that an increase in geometric complexity is not equally accompanied by an increase in costs. However, if the comparison is made within AM-processes, significant impacts regarding extended generation and post-processing time may occur, depending on the combination of process, material and geometry. Regarding material and machine parameters required for it, as well as the processing type/path generation, significant resource expenditures result (machine operating time, support structures). This influence also affects post-processing, since factors such as part accessibility are essential for the resulting material recovery, labour costs and processing time (especially for manual operations). Since AM is often on the edge of competitiveness compared to conventional processes, shape complexity can be a key factor accordingly. These effects are investigated using selective laser sintering technology exemplarily. As an application case, the production of orthopaedic shoe insoles is explained, where the geometry is built up individually for the customer, based on bionically inspired lattice structures. The adaptation of process parameters and process steps is presented in order to achieve a competitive production that enables an economic implementation of the underlying business model.
Speaker/s
Tobias Häfele htw Saar research associate
Tobias Häfele has been working as a research assistant and lecturer in the field of additive manufacturing at htw saar since 2015. He has been continuing his research at Saarland University since 2022. During his mechanical engineering study with specialization in "industrial production", he was already working on selective laser sintering for plastics, as well as hybrid component manufacturing. Since 2018, the research group has been working on the production of customized components, which are adapted using lattice structures, for instance. In this context, Mr. Häfele's research focuses on the effects of geometric complexity on the additive manufacturing process. The content is developed in close cooperation with local companies to ensure technology transfer and to open up new opportunities for competitiveness. In addition, he is pursuing this topic in his ongoing PhD at Saarland University at the Institute of Engineering Design.
17:00-17:30
Tool-, Model- & Mould Making
LIVE-STREAM (eng + de)
MJF applications for fluid systems and capital goods
Ralf Fischer // Karl Späh GmbH & Co. KG
de
Tool-, Model- & Mould Making
The SPÄH Group is a leading expert in rubber and plastics processing in Europe.
Thanks to our wide range of machining processes, large warehouse capacity, and almost endless variety of materials, we meet our customers’ individual requirements promptly and in accordance with the highest quality standards at our four locations in Germany.
We are also among the most innovative companies in the field of additive manufacturing.
Using HP’s latest MJF manufacturing technology, we can advise our customers across all areas of interest and implement additive manufacturing on demand.
In addition to the material polyamide 12 (PA12), which is characterized by high stability and impact resistance, we are also the first company to combine MJF technology with polypropylene (PP). Incredibly diverse and customized components are possible with these materials.
Especially in the field of fluid technology and capital goods, our expertise in deploying sophisticated combinations of complementary production technologies – in conjunction with a carefully coordinated range of materials – lets us break new ground in the application of additive manufacturing to series production.
Speaker/s
Ralf Fischer Karl Späh GmbH & Co. KG Coordinator Additive Manifacturing
Graduation:
Studies M.Sc. Automotive Engineering / Production Engineering (2013)
Professional background:
AMG RENNtec USA: Prototype development (2011 - 2012)
Independent additive production and application support (2013 - 2017)
Vocational training at the Robert Bosch School in Ulm: focus on AM technologies (2013 - 2016)
Solidpro GmbH (Bechtle AG): Application and field service engineer (2017 - 2021)
ETH Zurich: Project start Scientific Specialist Additive Manufacturing (2021)
In their talk bioDigital futures, Ana Goidea and David Andréen will share their vision of the future of 3D-printed architecture. The presentation covers two recent case studies, Protomycokion and Meristem Wall, exhibited at last year’s architectural exhibition in Venice. Both pieces explore performative meta-materials, functional integration, generative design, and high resolutions at construction scale. bioDigital futures brings together digital technologies with principles of biology to enable an innovative use of new materials and fabrication technologies. It invites a new relationship between human structures and the ecological world around us through interaction and collaboration with living agents.
Speaker/s
Ana Goidea Lund University
Ana Goidea is a PhD candidate at bioDigital Matter at Lund University, where she investigates the potentials of additive manufacturing in architecture through computational design. She received her Master of Architecture from CITAstudio at The Royal Danish Academy of Fine Arts, after which she has been teaching and working at studios with different strategies for digital fabrication. Her research met with industry through designing and co-fabricating one of the first 3d printed buildings in Europe. Her work explores the current relationship to the environment through the link between complex geometry and new material systems within digital computation and additive manufacturing technologies.
David Andréen Lund University Department of Architecture and Built Environment
David Andreen is a senior lecturer at Lund university where he leads the bioDigital Matter research group and is the director of the master’s programme in Digital Architecture and Emergent Futures. His research concerns architecture, digital fabrication and computation, with a particular interest in how principles of biology can help shape new sustainable paradigms in the design of the built environment. David did his doctorate at the Bartlett, UCL, investigating termite mounds as models for complex, functional form and related principles of emergence and self-organization. In addition to his current position in Lund, David has taught architecture at Greenwich University and the Bartlett, as well as being an invited critic and workshop leader across the world.
AM in User Practice
Clean and reliable metal powders – a statistical approach
Andreas Pelz // mp4 material solutions GmbH
de
AM in User Practice
Users of metal powder based additive manufacturing systems are often afraid of not receiving the right quality. And looking at the bulk of metal powder which shall be put in the machines it is definitely understandable that uncertainties exists: There are many factors affecting the powder quality and moreover which of them has an influence on the printing result? For many it feels like finding the needle in the haystack when being confronted with the question of potential contaminations which is of major concern when it comes to critical parts especially for aircraft solutions or medical applications. Aspects like individual quality sense of a supplier, experiences with prior deliveries or pro-active and extensive testing of each new batch can be found within the AM community. Within this presentation a new approach will be explained to overcome the worries by offering statistical based quality-numbers for metal powders.
Speaker/s
Andreas Pelz mp4 material solutions GmbH Manager
Metal powders are a guiding theme in the life of Andreas Pelz. The first more accidental point of contact came during his mechanical engineering studies and awakened his enthusiasm for powder metallurgy. In his first job as a development manager for wear protection materials, he was able to gain important practical insights into materials production and finally deepen his scientific knowledge in a part-time doctorate. During his doctorate, which focused on the optimisation of metal powder atomisation, he also came into contact with metallic 3D printing for the first time.
The guiding theme "metal powder" in combination with the fascination for additive manufacturing resulted in m4p material solutions GmbH in 2015. Accompanied by similarly fascinated team members, m4p is now leaving its mark worldwide as a "materials enabler" for metallic 3D printing!
Tableheader
Conference at Congress Center (chargeable)
Conference at Congress Center (chargeable)
Speaker/s
presentation programme in exhibition hall 2
presentation programme in exhibition hall 2
Speaker/s
09:00-09:30
Keynote: The Future of Mobility Interiors
LIVE-STREAM (eng + de)
The Future of Mobility Interiors
Bernhard Randerath // The Aviation AM Centre
de
Keynote: The Future of Mobility Interiors
Additive Manufacturing has the potential to enable new designs and functionalities in cabin interiors for various transport categories. As an example, a TWO NATIONS Project - The Decarb Factory for Mobile Interior will be presented, developing and manufacturing mobile interiors across different transport industries. In this context the keynote highlights the trends and introduces a Mobile Interiors factory of the future.
Speaker/s
Bernhard Randerath The German Emirati Institute Managing Director
Current jobs: CEO German Emirati Institute Chairman The Aviation AM Centre Location: Germany and United Arab Emirates
Past experience: 10 years: Vice president design, engineering and innovation Etihad Viation Group 13 years: Head and manager maintenance Systems Engineering / Design Airbus 3 years: manager and engineer trouble shooting / maintenance programmes Lufthansa Technik 4 years: Licensed AC technician maintenance and eingineering Lufthansa Westflug Aachen
Qualification: •Master Degree Aircraft Design •Judge panel member Chrytal Cabin Award •EASA Postholder Design P21J Aircraft Certification •Patents holder in the field of fault isolation and prognostics •International award winner in the field of new technologies •pilot and maintenance checker •President European Bonanza Society and Aircraft Association
09:30-10:00
Aviation
LIVE-STREAM (eng + de)
Certified Aviation Parts By Additive Manufacturing
Stephan Keil // The Aviation AM Centre
de
Aviation
The use of additive manufacturing in Aviation is still relatively new and subject to stringent regulation - however it is possible to establish a certified production system using AM and to unlock its benefits - this use case shows some examples and introduces The Aviation AM Centre's kurn-key solution for "Additive in Aviation".
Speaker/s
Stephan Keil The Aviation AM Centre GmbH Managing Director
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
News from AM - DED
LMD-wire application with adjusted process control
Dr. Frank Silze // OSCAR PLT GmbH
de
News from AM - DED
The LMD process with wire is increasingly used in industry due to its process-specific advantages. Compared to the already more established powder process, however, the wire process requires more comprehensive process control. The reason is the wire itself. The wire has to be molten 100% and needs permanent contact to the part surface. This leads to a relatively small process window, which must be kept stable by control mechanisms. The goal here is to allow the operator to increasingly become a passenger, similar to autonomous driving in road traffic. Ideas and solutions on the way there, such as the regulation of the working distance, the monitoring of the component contact or the specific control of the heat input, will be presented and discussed.
Speaker/s
Dr. Frank Silze OSCAR PLT GmbH Project manager additive technologies
2006 – 2012 Study Materials Science, TU Dresden 2012 – 2015 PhD thesis Leibniz Institute for Solid State and Materials Research Dresden - development of brazing alloys 2015 – 2016 Scientific Employee at IFW Dresden - additive manufacturing of metallic glasses (selective laser melting) 2016 – today Project Manager Additive Technologies at OSCAR PLT GmbH - process development Laser Metal Deposition
Co author: Sebastian Bibrack
AM Science
Process adapted simultaneous evaluation of the crystallization and flow behavior of PA 12 in laser sintering
Simon Cholewa // Universität Erlangen Lehrstuhl für Kunststofftechnik
de
AM Science
Plastic laser sintering is an additive manufacturing technology that meets require-ments of established manufacturing processes; thus, extending the original range of applications from prototype construction to functional components. Semi-crys-talline materials, mainly polyamide 12, dominate the market. During the building phase, material crystallization occurs yielding stresses due to volume contraction. In addition to crystallization-induced stresses, further stresses are induced in the material through shrinkage. This behavior is only observed via the termination criterion curling or the defect pattern warpage. Therefore, it is necessary to have a process-adapted evaluation to determine how long the molten polymer remains flowable, and at which point the stresses are stored in the material. A modified measurement setup of the rheometer with an ATR crystal allows simultaneous description of crystallization by FTIR spectroscopy, and measurement of the rhe-ological behavior of the material. The rheological behavior of polyamide 12 is studied during isothermal crystallization from the melt using dynamic oscillation experiments in a parallel plate rheometer. Relaxation experiments investigate the point where stresses are stored in the material. It is determined that the solidifi-cation of the melt is detectable at already low relative degrees of conversion, and that no stresses are accumulated in the material until this point.
Speaker/s
Simon Cholewa Lehrstuhl für Kunststofftechnik research assistant
Work History
Feb 2020- Present Scientific Assistant Institute of Polymer Technology Friedrich-Alexander University Erlangen-Nürnberg, Erlangen, DE
May 2019- Dec 2019 International Visiting Scholar Polymer Engineering Center University of Wisconsin Madison, Madison, WI
Oct 2018- Mar 2019 R&D Laser Applications Intern Fraunhofer CLA, Plymouth, MI
Sept 2015- Nov 2017 Manufacturing Management Engineering Student Co-op Robert Bosch GmbH, Bamberg, Germany
Oct 2015- Feb 2016 Global Procurement Intern Daimler AG, Esslingen, Germany
Education
Feb 2020- Present PhD—Mechanical Engineering Institute of Polymer Technology Friedrich-Alexander University Erlangen-Nürnberg, Erlangen, DE - Additive Manufacturing—Powder Materials, Project Manager
Oct 2016- Dec 2019 Masters of Science—Mechanical Engineering Friedrich-Alexander University Erlangen-Nürnberg, Erlangen, DE - Master’s Thesis: Investigation of Glass Bubble- Polyamide 12 Composite Properties for Selective Laser Sintering - Project Thesis: Investigations of Different Wavelengths in Laser Transmission Welding of Polymer Parts
Sep 2012- Oct 2016 Bachelors of Engineering—Industrial Engineering University of Applied Science, Schweinfurt, Germany - Final Paper: Implementation of industry 4.0 applications through change management at Robert Bosch GmbH
3D Printing Conference
Bauhaus, digitalisation & the promise of holistic design - looking at the present situation
Alexander Hoffmann & Thomas Schön // ARC Solutions GmbH
de
3D Printing Conference
Vor einhundert Jahren, auf dem Höhepunkt der Industrialisierung haben sich die Gründer des Bauhauses in Thüringen auf den Weg gemacht, den durch Arbeitsteilung fragmentierten Produktentstehungsprozess wieder zusammenzuführen. Seit den 1980er Jahres, ausgehend von CAD-CAM, hat die digitale Transformation von Produkt und Produktentstehungsprozess immer mehr Fahrt aufgenommen und aktuell mit Additive Manufacturing, Smart Product und Digitalem Zwilling eine neue Qualität erreicht. Der Vortrag diskutiert anhand ausgewählter Beispiele und der Siemens Xcelerator Plattform, wieweit wir uns dem ganzheitlichen Gestaltungsanspruch angenähert haben und wie sich beide Trends beeinflussen.
Speaker/s
Alexander Hoffmann & Thomas Schön // ARC Solutions GmbH
10:00-10:30
Aviation
LIVE-STREAM (eng + de)
The probation period is over. AM applications for aviation and aerospace industries are real now
Lars Langhans // FIT AG
de
Aviation
Additive manufacturing is able to provide the sought-for solutions to the predominant requirements aerospace is facing today: Cost reduction through simplified production processes, shortened production cycles, volume production, improved and innovative component design for weight reduction and functional optimization, and, last but not least, the reduction of CO2 emissions through fuel savings. If today the focus of additive manufacturing has shifted from prototype production to the real component ready-to-use, it is still true that small series or even one-offs are possible with additive manufacturing, which is a crucial prerequisite for the availability of needed parts. Which strengths come into play in each case for a project depends on the clear definition of the application and the intended improvement goals. Case studies of real applications such as a star tracker bracket made of aluminum and a fluid manifold made of Inconel show the wide variety of solutions that FIT has been able to develop for challenges for real customer projects, for example with TAI (Turkish Aerospace Industries), ArianeGroup and others.
Speaker/s
Lars Langhans FIT AG Head of Project Managment
After his studies of aerospace engineering, Lars has worked in different positions in engineering, sales and management of large and medium-sized industrial companies. With a comprehensive technical background in mechanical engineering and a particular specialization in aerospace, he discovered his passion for industrial 3D printing. Since January 2019, as Head of Project Management, he has dedicated himself entirely to the further development of additive manufacturing at the FIT Additive Manufacturing Group.
News from AM - DED
Development and Processing of Tailored Alloys by Extreme High-Speed Laser Material Deposition
Dr. Tobias Stittgen // Ponticon GmbH
de
News from AM - DED
New, application-specific materials are becoming increasingly important in additive manufacturing and coating of highly stressed components. While a large proportion of the alloys that can be processed today were originally developed for conventional manufacturing processes, additive manufacturing processes hold great potential in the development of application-specific materials. In nozzle-based laser material deposition, for example, powder materials can be combined in any composition and in-situ. In the laser powder bed fusion process, high cooling rates can be achieved thanks to high scanning speeds, which, for example, allow the microstructure to be influenced in a targeted manner. Thanks to feed rates of up to 200 m/min, extreme high-speed laser cladding (EHLA) is the first process to combine these two advantages. This makes it possible to process almost any combination of materials while specifically influencing the cooling conditions in the manufacturing process. The EHLA process thus holds great potential for the systematic, efficient development and testing of novel materials for additive manufacturing. In the course of the presentation, the relevant challenges, corresponding solution approaches and the first implementations of agile alloy development will be highlighted in detail and the steps towards sustainable, industrial application will be shown.
Speaker/s
Dr. Tobias Stittgen Ponticon GmbH Managing Director
Dr. Tobias Stittgen studied Industrial Engineering with a focus on production technology at RWTH Aachen University. After graduating, he held various positions in the Laser and Additive Manufacturing Industry, focusing on technology and sales activities. In 2021 he joined Ponticon GmbH, a provider of solutions for high-speed DED applications as Managing Director.
AM Science
Investigation of the influence of the ink application quantity on the part properties depending on the printed surface in High-Speed Sintering
Daniel Pezold // Universität Bayreuth
de
AM Science
The additive manufacturing processes of powder bed fusion of polymers (PBF P) have great potential for implementation in an industrial scale due to their productivity and scalability. In the PBF-P process High Speed Sintering (HSS), the polymer powder is fused by the combination of infrared absorbing ink, which is selectively applied to the powder bed surface by print heads, and an infrared (IR) lamp. Compared to laser sintering (LS), HSS enables a constant layer time regardless of the fill level of the build space. In addition, the new design possibilities of the local part and material properties through the variation of the energy input, which can be adjusted via the ink application quantity, should be emphasized. In this research work, the influence of the ink application quantity on the part properties of polyamide 12 (PA12) parts is investigated. For this purpose, two different methods for controlling the ink application quantity - grayscale and dithering - are applied in combination. To assess the influence of the ink application quantity on the part properties, test specimens are evaluated with regard to the criteria of density, geometrical and dimensional accuracy, degree of fusion, mechanical and thermal properties. The evaluation of the results showed that the ink application quantity has a significant influence on the part properties and that a setting of ink application quantities between 1.200 and 3.000 pl/mm2 results in good part properties.
Speaker/s
Daniel Pezold Universität Bayreuth research assistant
Apprenticeship/studies: - 10/2011 – 03/2014: Master University of Stuttgart (Mechanical Engineering - Materials and Production Engineering – specialization ceramic, composites and surface technology) - 04/2014 – 08/2014: Internship STIHL Inc. USA as project engineer - 09/2014 – 02/2017: Project engineer in production development STIHL Switzerland - 03/2017 – today: Research associate at the University of Bayreuth (Additive Manufacturing, AM) – Project Manager Current work: - Project manager “Application center 3D-Printing Upper Franconia” - AM of Endless fiber reinforced plastics - AM of Water soluble cores for CFRP - Material development for high speed sintering Other data: - planed PhD thesis until 2022: “Development of a new infrared absorbing fluid for high speed sintering (HSS)”
3D Printing Conference
Additive manufacturing in an industrial environment
Étienne Luimes // Mark3D GmbH
de
3D Printing Conference
Die Additive Fertigung mit Markforged und Materialien wie Glasfaser, Carbon oder Kevlar ermöglicht es Ihnen, echte Probleme zu lösen und zahlreiche Bauteile zu fertigen, die Sie zerspanen müssen, aber eigentlich nicht zerspanen wollen. Das ist Fertigung neu definiert. Verfügbarkeit. Unabhängigkeit. Innovation.
Speaker/s
Étienne Luimes // Mark3D GmbH
10:30-11:00
Coffee Break
Coffee Break
Speaker/s
11:00-11:30
Aviation
LIVE-STREAM (eng + de)
Secure on-demand Manufacturing for aviation
Nils Gerlant Veenstra // AMbrace
de
Aviation
In this session Nils will explore the opportunities and challenges Additive Manufacturing brings when a global aviation company is looking to re-invent its parts strategy and supply chains.
By taking you on a journey in a real-world business case featuring KLM we will be able to identify clear opportunities (including, but not limited to lower part costs and increased business continuity), clear challenges (such as limits to technology and skill sets, data security, IP and licensing management), and impactful consequences in business logics (such as the creation of new revenue streams, and changing dynamics with suppliers and vendors in the value chain).
We will explain how a particular business case in the aviation industry has prompted a software company to start developing entire vertical value chains with multiple stakeholders to come to a complete solution for its customers and partners. In order to develop a digital parts strategy, interoperability across the entire value chain is needed to ensure trust in IP, trust in quality and trust in transactions.
Speaker/s
Nils Gerlant Veenstra AMbrace Chief Strategy Officer and Co-Founder
November 2021 – Present CEO at Industriam (Haarlem, Netherlands and Aachen, Germany)
June 2020 – Present Chief Strategy Officer at Ambrace (Rotterdam, Netherlands)
Until June 2020 Global CEO at New Alchemy (Seattle, USA)
News from AM - DED
DED-based hybrid production system for spare parts
Marcus Witt // Metrom
de
News from AM - DED
On the basis of an existing 5-axis parallel kinematic machine system suitable for the mechanical processing of easy to difficult-to-machine materials, an integration of an arc buildup welding process (WAAM) was carried out by means of a quick-change system. This allows a component to be manufactured additively in the same clamping situation as well as to be intermediately machined and reworked. One advantage of this is that the time-consuming measurement of an additively manufactured component by means of a scan to define the zero point and a best fit are no longer necessary. There are no limitations with regard to the manufacturer of the welding system. A component was implemented as a spare part for the oil and gas industry. This was tested with regard to the construction strategy, material usage, generation and cooling strategy and forms the basis for the presentation. An evaluation of the results achieved, the limitations encountered and an outlook on the need for further research are presented as examples. Further post-processing possibilities will also be shown and the transferability to the field of hybrid manufacturing using plasticized plastics will be presented.
Speaker/s
Marcus Witt METROM Mechatronische Maschinen GmbH Technical development and sales
Marcus Witt, born 1984 in Karl-Marx-Stadt, studied mechanical engineering at the TU-Chemnitz from 2003 to 2008. After graduating, he worked at pro-beam AG & Co. KGaA as welding supervisor until 2010 and then as technical sales in electron beam and laser special machine construction and was in particular key account automotive at pro-beam systems GmbH until 2015. In the following then the position as CSO/ Head of Sales of pro-beam systems GmbH until 2017. Since February 2017 he entered the family-owned and operated company METROM Mechatronische Maschinen GmbH until today. Since April 2020, he is also managing director of 1A Technologies UG for the industrialization of components for 3D printing, in particular the SEAM process patented by Fraunhofer IWU.
AM Science
An Optical Tomography Based Study on the Influence of Different Gases During PBF-LBM: Distribution of Process By-Products and Part Properties
Tobias Deckers // Linde GmbH
de
AM Science
The present work investigates the influence of different process gases on the formation of by-products during Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) for a Nickel-Chromium alloy. Primarily the study was placed on argon (Ar) and various argon-helium (Ar-He) mixtures as process gases.The trials were performed on an EOS M290, which was equipped with an optical tomography (OT) monitoring system. In the first part of the study, a methodology for a qualitative evaluation of process by-products through OT monitoring was adapted and applied to enable particle tracking. The algorithm was designed primarily to show the distribution and interaction zones of process-by-products Afterwards, PBF-LB/M trials with cuboid test specimens were performed and evaluated. First results using the OT monitoring system showed a reduction of the amount of process by-products and their thermal radiation when using Ar-He gas mixtures compared to pure argon. Furthermore, typical part properties (e.g., density) were at least equal to argon or could be improved with the use of helium contents.
Speaker/s
Tobias Deckers Linde GmbH
School Education / Academic Career
09/2019 – 05/2021 Master of Science, Mechanical Engineering University Duisburg - Essen Major: Product Engineering Master thesis: Research on the influence of shielding gases on a nickel-chromium alloy using PBF-LB/M
10/2013 – 08/2019 Bachelor of Science, Mechanical Engineering University Duisburg - Essen Major: General Mechanical Engineering Bachelor thesis: Qualification of polybutylene terephthalate for laser sintering process by particle design based on statistical experimental methods
Since 06/2021 Doctoral Candidate & Research Associate at University Duisburg-Essen / Linde GmbH Research about gas influences in the field of Additive Manufacturing
10/2020 – 04/2021 Masterand at Linde GmbH - Development Center Research on the influence of shielding gases on a nickel-chromium alloy using PBF-LB/M
07/2019 – 09/2020 Research Assistant at the Chair of “Manufacturing Technologies”, University Duisburg-Essen Cooperation in research and development projects (main topics: Industry 4.0, Hybrid Assembly, Simulation and Lean Management)
08/2017 – 06/2019 Student Assistant at the Chair of “Manufacturing Technologies”, University Duisburg-Essen Design and construction of test facilities, material qualification, process development in the field of laser sintering
3D Printing Conference
3D printing and high troughput manufacturing of transparent glass
Patrick Risch // Glassomer GmbH
de
3D Printing Conference
Glassomer GmbH is a young start-up that wants to revolutionize the structuring of glass in the 21st century. Our company invented the so-called "Glassomers", that can be 3D printed or injection molded for mass manufacturing. After a subsequent heat treatment, the parts are turned to 100% fused silica glass.
Speaker/s
Patrick Risch // Glassomer GmbH
11:30-12:00
Aviation
LIVE-STREAM (eng + de)
Applications and Quality Assurance for Additive Manufacturing with aviation perspective
Dr. Jürgen Kraus // MTU Aero Engines AG
de
Aviation
The presentation gives an overview about development of Additive Manufacturing at MTU. The technologies to be developed for the whole process chain are discussed. The first typical applications are presented and assessed regarding their service behavior. Another key aspect of the presentation is quality assurance for AM. An overview about the complete QA-system is given and crucial components are discussed in detail. Primarily the non-destructive testing chain belongs to that group comprising of on-line process monitoring and X-rax.
Speaker/s
Dr.-Ing Jürgen Kraus MTU Aero Engines AG Head of additive manufacturing
Studies of production engineering and conferral of a doctorate in the field of laser material processing at University Erlangen-Nürnberg Start as a turbine development designer at MTU Aero Engines in 1998 Team leader design standards 2001 – 2003 Team leader rotor design 2004 - 2007 Team leader airfoil design 2008 - 2011 Engineering director at MTU Polska 2012 - 2015 Senior consultant additive manufacturing 2016 - 2017 Director additive manufacturing since 1st of January 2018
News from AM - DED
Wire electron beam additive manufacturing
Dr. Bernd Baufeld // pro-beam additive GmbH
de
News from AM - DED
Wire Electron Beam Additive Manufacturing (WEBAM) is capable to provide semi-finished products of materials, which are challenging for other additive manufacturing technologies. The advantages of WEBAM are related to the specific properties and capabilities of the electron beam, and to the operation in a high vacuum. WEBAM is the ideal additive manufacturing technology for refractory metal with high oxidation activity and high melting point (Ti, Zr, Ta, …) and metals with high light reflectivity (Cu).
Speaker/s
Dr. Bernd Baufeld pro-beam additive GmbH Process developer
Material scientist in the area of titanium, steels, superalloys, thermal barrier coatings, oxide ceramics, quasi crystals
Author of more than 100 scientific publications, whereof 25 regarding additive manufacturing
At pro-beam: Process developer for wire electron beam additive manufacturing (WEBAM), same subject since 2015 at the Nuclear AMRC, Sheffield, since 2007 mechanical testing and microstructural analysis of WAAM components (KU Leuven)
since 04/19 pro-beam, Gilching, Deutschland
09/10-03/19 Nuclear AMRC, University of Sheffield, UK
02/01-09/05 Institut für Werkstoffforschung, DLR, Köln, Deutschland
02/99-01/01 Institute for Advanced Materials of the Joint Research Centre of the European Commission, Petten, Netherlands
09/98-01/99 Institut für Werkstoffwissenschaften der Friedrich-Alexander-Universität Erlangen-Nürnberg, Deutschland
11/96-08/98 Max-Planck-Institut für Metallforschung, Stuttgart, Deutschland
01/97-12/97 Japan Science and Technology Corporation (JST), Nagoya, Japan
11/91-10/96 Max-Planck-Institut für Mikrostrukturphysik, Halle/Saale, Germany
10/96 promoviert an der Martin-Luther-Universität Halle/Wittenberg, Deutschland
11/85-06/91 Physikdiplom, Bayerische Julius-Maximilians-Universität Würzburg, Deutschland
08/88-05/89 Master of Science, State University of New York at Albany, USA
AM Science
Computational design of a high y' nickel based superalloy for LPBF
Philipp Stich // EOS GmbH
de
AM Science
In accordance with recent efforts to make new alloys available for AM processes, this study contributes to the development of a methodology for alloy development through a combination of computer-aided and physical alloy screening. The focus is on high y'-content nickel-based superalloys. Due to high solidification intervals of these alloys, segregation phenomena occur in the manufacturing process, which can lead to hot cracks and should therefore be reduced or avoided completely. By combining physical modelling approaches and computer simulation with state-of-the-art sample production and analysis, a fundamental understanding of the segregation behaviour of the reference alloy CM247LC in the LPBF process is generated.
The project includes the development of a screening tool to automatically identify possible alloy candidates by thermodynamic calculations (CALPHAD) and compare them using various criteria. An AM-modified version of CM247LC is identified as the target alloy, which is less susceptible to process-induced hot cracking, while having similarly good mechanical properties in the high-temperature range. This AM modification is produced, materially characterised, and compared to the initial state.
To be able to make a better selection of the calculated alloy candidates, elements critical to hot cracking are identified by process and microstructure simulation. The thermal process conditions, which are essential for the simulation of the microstructure (phase field), are calculated by process simulation (FEM). The segregation behaviour is correlated with the energy input, depending on the process parameters. The validation of the results is carried out using data from the experiments as well as the results of comprehensive microstructural investigations.
Speaker/s
Philipp Stich EOS GmbH PhD Student
Education
2000-2004 Grundschule Richterich, Aachen
2004-2013 Kaiser-Karls-Gymnasium, Aachen
2014-2017 Bachelor of Science (Overall mark 2,2 - Deans List Award) Business Administration and Engineering: Materials and Process Engineering, RWTH Aachen
2017-2020 Master of Science (Overall mark 1,8) Business Administration and Engineering: Materials and Process Engineering, RWTH Aachen Specialization: Non-ferrous metals & metal recycling
2020-today PhD Student EOS GmbH Electro Optical Systems, Krailling München Concepts for the prevention of hot cracks in Nickelbased-Superalloys
Work Experience
07/2008 NATO Airbase, Geilenkirchen: two-week internship
2009-2012 Forschungsinstitut für Rationalisierung (FIR), Aachen: temporary employment
2018 Institut für bildsame Formgebung (IBF), RWTH Aachen: three-month bachelor thesis in strip casting „Influence of casting roll structuring on surface quality and mechanical properties of strip-cast, high manganese steels containing aluminium"
03/2019 Service Innovation Award 2019 of the Walter-Eversheim-Stiftung, FIR Aachen (1.Place)
2016-2019 Institut für bildsame Formgebung (IBF), RWTH Aachen: student assistant Main focus: Preparation and post-processing of strip casting tests, material characterisation, microstructure analyses, preparation and execution of rolling tests.
2019-2020 BMW Group, München: three-month internship in the area of additive manufacturing Main focus: material characterization
2020-heute BMW Group, München: six-month master thesis Main focus: Binder Jetting „Experimental investigation of the influence of sintering and heat treatment parameters on the orientation dependence of the mechanical properties of 17-4 PH Binder Jetting samples“
3D Printing Conference
Additiv manufactured gripper tool with integrated sensors
Elisa Sachse // Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS
de
3D Printing Conference
Die additive Fertigung beschäftigt sich zunehmend mit der mechanischen und elektrischen Funktionalisierung (Multimaterial, Sensoren, Leiterbahnen) generativ gefertigter Bauteile. Im Folgenden wurde ein additiv gefertigter intelligenter Greiferfinger, basierend auf dem FinRay-Effekt, in Kombination mit integrierter gedruckter Sensorik entwickelt. Die mechanische Funktionalisierung durch den FinRay-Effekt bietet die Möglichkeit, verschiedene Geometrien und Materialien sicher und nahezu Formunabhängig zu greifen. Die elektrische Funktionalisierung hingegen liefert Informationen zur Greifkraft und Objektnähe und ist in einen Regelkreis integriert. Innerhalb des Fused Filament Fabrication (FFF) Prozesses können zum Einbetten von Leiterbahnen in 3D-gedruckte Bauteile metallische Pastensysteme verwendet werden, die mittels Dispensdruck appliziert werden. Diese sind aufgrund hohen Leitfähigkeit im Vergleich zu leitfähigem Filament effizienter und werden als Verbindungsmaterial zwischen elektronischen Bauteilen wie Temperatur-, Druck- und Feuchtigkeitssensoren oder als Heizelement eingesetzt. Zur Funktionserweiterung des AM FinRay-Greiferfingers wurden verschiedene Sensoren entwickelt, die mit der Prozesskombination aus Dispensdruck und FFF appliziert und auf ihre Funktion untersucht wurden. Die Anwendungsbereiche umfassen Lebensmitteltechnik, Tiefseeforschung und Weltraumanwendungen.
Speaker/s
Elisa Sachse // Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS
12:00-12:30
Aviation
LIVE-STREAM (eng + de) Full 3D Ends in Manual Work?
Thomas Bielefeld // Premium Aerotec GmbH
de
Aviation
Additive Manufacturing of metals is seen as key technology for future eco-efficient and sustainable lightweight designs in mobility. Full 3D design and production would be possible if there would be no need for manual removal of supports and surface finish. Especially the enormous design freedom in fact cannot be used considering the efforts in reworking topology-optimized structures. The presentation investitigates the gap between full 3D expectations, which end in manual work, derives different approaches to minimize or even overcome the mentioned gap and provides a roadmap to achieve full benefit of AM technology.
Speaker/s
Thomas Bielefeld Premium Aerotec GmbH Senior Expert AM
In 1993 he started his professional career as research engineer at the LEIBNIZ Institute for Material-Oriented Technologies (IWT). He managed national and international research projects and headed an engineering team focussed on process innovation and process chain reductions. After his PhD on short-time metallurgical effects in metals Thomas was awarded the International CIRP Taylor Medal in 2000. Since 1999 he took leading positions in different industries. For ASTRIUM Space he served as Head of Production Center Tanks & Components with responsibility for satellite propulsion equipments like tanks, valves, thrusters, tubings and insulation. Joining AIRBUS in 2006 he get in charge of the competence center for production systems, an annual 65 M€ business on developing and producing advanced jigs & tools for carbon fiber placement and aircraft assembly lines. With foundation of Premium AEROTEC 2009 Thomas served the Board of Management on several improvement projects. As Head of Supply Management Detail Parts and Aerostructures he implemented new order and operational supplier management processes. 2015 PAG decided to industrialize Additive Manufacturing for aerospace serial production and Thomas lead the activities on technology development, process maturity and reproducibility, qualification, automation and digitalization. His scientific and technological background is mainly in the field of short-time metallurgical effects in material removal and thermal processes, electron-beam welding and heat treatment of titanium alloys, laser welding and heat treatment of aluminium alloys and PBF-LBM of titanium/aluminium. He lives in North Germany, is married and has 5 children.
News from AM
3D Printing / Additive Manufacturing in Mechanical Engineering
Philipp Götz // Götz Maschinenbau GmbH & Co.KG
de
News from AM
Speaker/s
Philipp Götz Götz Maschinenbau GmbH & Co.KG CEO
2006 A-Level
2006 - 2007 civilian service
2007 - 2011 academic studies at HDU Deggendorf as a Mecanical engineer
Additive manufacturing of chemical reactors by Bound Metal Deposition
Leighton Clague // Technische Universität Hamburg (TUHH) - Institut für Laser- und Anlagensystemtechnik (iLAS)
de
AM Science
Chemical reactor packing structures have seen recent innovations through their embrace of additive manufacturing (AM). The increased design freedom enabled by AM has seen an array of new cell structures being implanted. One drawback, however, is the increased respective cost of produced these novel structures when produced using powder bed fusion (PBF), especially with respect to the large amount of packing required to fill an industrial chemical reactor. Bound Metal Deposition (BMD) has emerged as a cost-effective AM process. This study investigates the possibility to produce such packing structures using BMD. To conduct a preliminary assessment of the suitability of chemical reactor packing manufacture with BMD, a batch of samples was produced using both PBF and BMD. These samples were then compared with measurements of parameters relevant to the application case, particularly dimensional accuracy. These experiments provide the groundwork for further testing with these packing structures, with the intention to compare them against each other in a full-scale chemical reactor.
Speaker/s
Leighton Clague Technische Universität Hamburg (TUHH) - Institut für Laser- und Anlagensystemtechnik (iLAS) research associate
Professional Experience
Research Associate, iLAS at the TUHH, Hamburg — 07/2021 – present
Working Student, Fraunhofer IAPT, Hamburg — 07/2020 – 08/2020
Research Assistant, IPMT at the TUHH, Hamburg — 10/2019 – 12/2019
Education
Hamburg University of Technology (TUHH) — M.Sc. 10/2018 – 06/2021 M.Sc. Mechanical Engineering and Management Major: Product Development and Production + Management Project Thesis: Additive Manufactured Cooling Plate for Electronics Master Thesis: Application of TPMS Structures Manufactured by Bound Metal Deposition
University of Melbourne, Australia — B. Sc. 02/2015 – 12/2017 Major: Mechanical Systems Exchange Semester: Universität Stuttgart
3D Printing Conference
Color-matched 3D printing - CMJ (Color-Material-Jetting) at its best.
Uwe Niklas // DP Solutions GmbH & Co. KG
de
3D Printing Conference
Im 3D-Druck mit Farbe gibt es noch viele offene Fragen. Sind 10 Millionen Farben wirklich möglich? Wie kommen die Farben an das Bauteil und welche Datengrundlage ist notwendig? Wir beantworten alle Fragen rund um 3D-Druck mit Farbe .
Speaker/s
Uwe Niklas // DP Solutions GmbH & Co. KG
12:30-13:30
Lunch Break
Lunch Break
Speaker/s
13:30-14:00
Keynote: Autodesk
LIVE-STREAM (eng + de) The Autodesk Machine Control Framework
Alexander Oster // Autodesk
de
Keynote: Autodesk
The Autodesk Machine Control Framework is an open source software stack to integrate several hardware subsystems into a production-ready, complete and cohesive closed loop system, that can produce laser-based additive parts out of the box. Thanks to the outstanding collaboration between SCANLAB, the leading provider of hard- and software of laser controls, and Autodesk Inc., one of the leading providers of CAD/CAM/CAE software for Manufacturing, any engineering organisation with a background in mechanical hardware can quickly combine the Autodesk Software stack together with SCANLAB’s leading edge technology and to create a beyond-state-of-the-art industrial system with a fraction of the traditional effort.
Enriched with build processors, support generators, a modern browser-based Human Machine Interface, configurable Open APIs and unseen features like over-the-air updates and transactional timeline journaling, the framework reduces the costs and time-to-market for any machine builder in a similar way to what Android did for the mobile phone industry during the last decade.
The talk will highlight the detailed architecture and will give a blueprint of how an industry 4.0 system should function. And it will as well showcase the features and capabilities a compact system can expose if it is written from scratch – especially with the inclusion of the best practices of thousands of developer years that only a multinational software giant like Autodesk can apply.
Speaker/s
Alexander Oster Autodesk Director Additive Manufacturing
Experience
Additive Manufacturing - Autodesk Nov. 2015–today
Leading the Netfabb Team in the Fusion 360 Manufacturing group. Chairman Technical Working - 3MF Consortium
Apr. 2015–today
CEO - netfabb GmbH 2009–today
CTO - FIT Additive Manufacturing Group Sept. 2014–Nov. 2015
Software Developer - FIT - Additive Manufacturing Group 1998–2009
Education
Brandeis University Mathematics, Computer Science 2007–2008
Universität Regensburg Mathematics, Physics, Chemistry 2003–2008
(Kopie 17)
3D Printing Conference
Future Electric Motor Systems 3 - Aerospace Motor
Ollie Hartfield // Manufacturing Technology Centre - MTC
de
3D Printing Conference
The movement to replace fossil fuels with sustainable energy sources will be a key contributor to decarbonising industry and reduce the impact of climate change. To address the challenges surrounding this transition, the FEMS 3 Aerospace motor explores the benefits of additive manufacturing to produce a high performance, power dense electric motor with the aim of significantly reducing lifetime emissions for a more sustainable product. To achieve this, advanced design tools are explored to generate highly optimal components with a streamlined workflow.
Speaker/s
Ollie Hartfield // Manufacturing Technology Centre - MTC
14:00-14:30
Aviation
LIVE-STREAM (eng + de)
State of knowledge and qualification of 3D-Printing for New Space
Jaime Aguirre // Rocket Factory Augsburg AG
de
Aviation
The need for real-time processing of very large amounts of data via satellite-supported systems is extremely high. For the year 2040, a market volume of more than 1 trillion euros is expected in the "New Space" sector. The global, location-independent availability of large amounts of real-time data opens technological and economic opportunities and potential like never before. The realization of applications in the "New Space" area depends decisively on the fast and cost-effective series production of new propulsion systems. To achieve this, the price-performance ratio of the carrier systems must be significantly increased.
A change in the price-performance ratio is due to new materials and innovative production methods such as metal 3D-Printing possible, which is due to more powerful cooling through internal cooling channels can be used at significantly higher temperatures and also save weight. The engine components of small rockets are already being manufactured using 3D-Printing. This lecture will deal with the current state of knowledge and qualification of 3D- Printing for New Space.
Speaker/s
Jaime Aguirre Rocket Factory Augsburg AG Development Engineer - Additive Manufacturing
Career since September 2021: Development Engineer - Additive Manufacturing, Rocket Factory Augsburg April 2021 – August 2021: Intern Additive Manufacturing Engineer, Rocket Factory Augsburg October 2019 – March 2021: Research Assistant in Additive Manufacturing at Fraunhofer IGCV
News from AM
Precision Titanium components made by sinter based 3DP technologies, from Prototype to Production
Matthias Scharvogel // Element22
de
News from AM
The relatively new sinter-based 3DP technologies allow manufacturing precision Titanium components with excellent material properties and good surface finish in an economic fashion. The manufacturing technologies are interesting for prototypes through production quantities and used in many different industry segments.
Speaker/s
Matthias Scharvogel Element22 CEO
CEO Titanium Generation GmbH, Nov 2017 – Present Jena & Hamburg
CEO Element 22 GmbH Aug 2011 - Present Kiel, Germany
General Manager TiJet Medizintechnik GmbH 2009 - 2011 ·
Vice President Heraeus 1994 - 2006
Education
Thunderbird University, The Garvin School of International Management - Glendale, AZ Executive Master of Business and Administration; 2006
Effective polishing of inner surfaces of additive manufactured inserts for plastic extrusion using Plasma Electrolytic Polishing
Kristina Navickaitė // TU Bergakademie Freiberg
de
AM Science
While additive manufacturing enables fast production of parts with high geometrical complexity, the post-processing step for obtaining high-quality surfaces of these parts is getting increasingly difficult. In addition, not all state-of-the-art polishing techniques are capable of achieving satisfactory results. Moreover, many of them are extremely environmentally unfriendly. In this study it was demonstrated that effective and more environmentally friendly polishing of inner surface of parts additive manufactured from maraging steel 1.2709 powder could be achieved by employing immersion-based plasma electrolytic polishing. In total two parts having different gap size were investigated. After 10 min of polishing the inner surface roughness was reduced from maximum Ra = 6.53 μm to minimum Ra = 0.53 μm.
Speaker/s
Kristina Navickaitė TU Bergakademie Freiberg research assistant
Education
01/09/2009 – 24/06/2013 Kaunas University of Technology (KTU) BSc in Building Services Systems. Qualification: Bachelor of civil engineering.
01/09/2013 – 13/01/2015 Kaunas University of Technology (KTU) MSc in Building Services systems (along with Rector’s acknowledgement). Qualification: Master of civil engineering.
14/12 /2015 – 14/12/2018 Technical University of Denmark (DTU) Doctor of Philosophy in technical sciences for the PhD thesis “Nature-inspired double corrugated geometry for enhanced heat transfer”
Work experience / research activities
02/2012 – 06/2012 Project for promoting student research activity 2012 Project: “The aesthetic visual expression and security of Lithuanian highways landscape”
07/2012 – 12/2012 Department of Architecture and Landscape (KTU) Project: “Three-dimensional structure of the city and public safety”
03/10/2012 – 01/07/2013 “Virmalda“ Ltd Occupation of technician of designing.
08/07/2013 – 17/09/2015 “TERMA“ Ltd Occupation of engineer/designer.
01/01/2019 – 31/03/2019 Technical University of Denmark (DTU) Research assistant at Department of Energy Storage and Conversion, Section of Continuum modelling and testing.
01/05/2019 – 30/04/2020 Fraunhofer – Gesellschaft International guest researcher (Postdoc) at Fraunhofer – Gesellschaft IFAM.
01/05/2020 – 14/04/2021 Beckmann Institute for Technology Development Research engineer
15/04/2021 – 30/06/2021 University of Ljubljana, Faculty of Mechanical Engineering Assistant PhD
01/07/2021 – now Technical University Bergakademie Freiberg Researcher
Additional activities
01/09/2017 – 22/12/2017 External research stay at KTH Royal Institute of Technology, Sweden The research work in prof. B. Palm group working on magnetic refrigeration.
21/04/2018 – 05/03/2018 External research stay at the University of Parma, Italy The research work in assoc. prof. F. Bozzoli and prof. S. Rainieri’s group working on heat transfer in double corrugated tubes.
15/11/2019 – 14/10/2019 External research stay at Technical University of Denmark, Denmark The research work in assoc. prof. K. Engelbrecht and assoc. prof. C. Bahl’s group working on performance assessment of 3D printed magnetocaloric regenerators under active and passive experimental conditions.
05/2020 – now Volunteer at the International Institute for Refrigeration (IIR) Responsible for writing an informatory note on district cooling Responsible for writing an encyclopaedia article on additive manufacturing for caloric cooling.
3D Printing Conference
Partbox - Click and Print
Moritz Schmitz // Schubert Additive Solutions GmbH
de
3D Printing Conference
Partbox is the first part streaming plattform for Additive Manufacturing, which offers the user the fastest and easiest way to print spare parts and parts directly at his site. The Partbox eco system contains everything the user needs to produce industrial grade quality parts without prior knowledge of Additive Manufacturing. The free to use license generator enables different OEM´s to give away print-licenses for their parts without losing control of their intellectual property.
Speaker/s
Moritz Schmitz // Schubert Additive Solutions GmbH
14:30-15:00
Aviation
LIVE-STREAM (eng + de)
Robot Guided Additive Manufacturing for Aerospace Applications
Dr. Jan-Ole Kühn // Zentrum für Angewandte Luftfahrtforschung
de
Aviation
Robot-guided additive manufacturing enables hybrid designs, very large print volumes and non-planar 3D printing. It is precisely this potential that is essential for aircraft cabin components and offers new design possibilities. For this, material selection, providing process conditions, process control and process monitoring are crucial to ensure component quality. The material selection for aerospace applications coupled with the processing of these materials in an open lab environment is investigated by two robotic systems, one producing components on a filament basis and the other on a pellet basis. The focus is on process control in combination with process monitoring. In addition, this opens up enormous potential for the functionalization of components, for example through the nonplanar printing of conductive tracks on a polymer component for the operation of loudspeakers and other electrical components. Automated manufacturing through the use of robots is also a forward-looking way to produce functional, individual large structures for aircraft cabins.
Speaker/s
Dr. Jan-Ole Kühn Zentrum für Angewandte Luftfahrtforschung Technical Manager Advanced Materials
Professional Experience
Technical Manager Centre for Applied Aeronautical Research, Hamburg 01/2022 - ongoing
Senior Development Engineer Centre for Applied Aeronautical Research, Hamburg 07/2020 – 12/2021
PhD-Student thyssenkrupp Steel Europe AG, Duisburg 03/2017 - 06/2020
Academic Educaion
Doctoral Candidate University of Duisburg-Essen, Essen 2017 - 2020
Master’s in Analytical Chemistry Leibniz University, Hanover 2014 - 2016
Bachelor’s in Chemistry and Biotechnology Focus: Chemical Analysis and Laboratory Management Niederrhein University of Applied Sciences, Krefeld 2014 - 2016
News from AM
Most Wanted: New AM Metal Materials
Gregor Graf // Rosswag
de
News from AM
The very limited choice of materials for metal 3D printing is a key obstacle to the industrialization of this disruptive manufacturing technology. More qualified materials lead to more industrial applications, for example in lightweight construction, which have great potential for increased resource and cost efficiency over the product life cycle by means of function-optimized component geometries. Through an innovative process chain with attached metal powder production, new materials for metal 3D printing can be qualified to a high level of industrial maturity with minimal time and resource input. Thus, more users from different industries can be enabled to use additive manufacturing technology advantageously in the shortest possible time. Examples of qualified materials and implemented applications demonstrate this potential and provide a positive outlook regarding the further development of additive manufacturing technology.
Speaker/s
Gregor Graf Rosswag Head of Engineering
Gregor Graf studied mechanical engineering at the Karlsruhe Institute of Technology (KIT) and wrote his master thesis on metal 3D printing in 2014. Since completing his studies, he has been responsible for all activities in the field of additive manufacturing at the medium-sized family-run company Rosswag GmbH as head of the division Rosswag Engineering with a fast growing team of 15 employees. Here, the LPBF technology is applied in a holistic process chain from metal powder production to material analysis. Meanwhile more than 40 materials were qualified in-house for LPBF and 60.000 parts were produced for a broad range of end customers and industrial applications.
AM Science
Systematic process-model for the redesign of topology optimized structures for additive manufacturing – node-rod-shearfield-approach (KS²-approach)
Ali Al-Zuhairi // Technische Universität Kaiserslautern
de
AM Science
Topology-optimization (TO) is a versatile tool for designers to create load-appropriate and lightweight designs for structural components. However, the mesh-based algorithms usually tend to generate inconsistent structures that cannot be manufactured directly, even with additive manufacturing processes. Due to this, KS²-approach was developed which takes central issues of the reconstruction process into account, such as the interpretation and parametric return of the TO-drafts. KS² is derived from several TO components where five general substructures are defined. The relationship from the substructures to the overall context to TO is represented in an ontology. On the basis of the substructures, a systematic process model is propagated to enable more efficient additive manufacturing.
Speaker/s
Ali Al-Zuhairi Technische Universität Kaiserslautern research assistant
Mr. Al-Zuhairi studied mechanical engineering at the RheinMain University of Applied Sciences in Rüsselsheim. First, the Bachelor with B.Eng. in 2016 and afterwards the dual Master in 2018 with the M.Eng, in the specialization "Product Development and Manufacturing". Since February 2019, he has been a research assistant at the Institute for Mechanical and Automotive Design at the Technical University of Kaiserslautern, where he focuses on the following topics: Design and simulation, especially for additive manufacturing.
15:00-15:30
Aviation
LIVE-STREAM (eng + de)
Flame-retardant materials for transportation
Dr.-Ing. Matthias Fischer // BASF 3D Printing Solutions GmbH
de
Aviation
Additive Manufacturing is already used in many applications such as jigs and fixtures in production facilities where the design freedom, variety of part designs or short lead times are required. The transportation industry is also an example where the benefits of Additive Manufacturing (AM) seem to be a perfect match, nonetheless the high-end certification requirements of this industry creates a high entry barrier for AM equipment manufacturers, material and part suppliers. BASF Forward AM provides AM materials in form of liquid photopolymers, powders and filaments. One of the key features for plastic applications specifically in transportation is the flame retardancy of the material. BASF Forward AM currently offers four flame retardant plastic filaments in different price ranges and for different AM equipment specifications. Further materials focused on the flammability behaviour are under development. This presentation will give insights to industry related material test methods as well as examples of potential applications. BASF Forward AM not only offers a filament but rather a holistic approach by providing a wide range of material data, support in certification processes (e.g. railway or aerospace) and technical support for individual applications.
Mr. Dr.-Ing. Matthias Fischer finished his masters program in Mechanical Engineering at the University of Paderborn with main study in Polymer Engineering in 2013. Immediately after this, he worked for the Chair of Polymer Engineering at the University of Paderborn. In Cooperation with the Direct Manufacturing Research Center (DMRC) topics of his research were the fatigue behavior and surface treatment of Fused Deposition Modeling (FDM) parts, which were also the focus of his dissertation from 2019. Mr. Fischer works since September 2017 for the company BASF 3D Printing Solutions GmbH with headquarter in Heidelberg where he leads at the present moment the application technology for plastics filaments at the enterprise location in Emmen, The Netherlands.
News from AM
Spotmelting: New melting strategies with EB-PBF
Peter Jain // Freemelt AB
de
News from AM
Using electron beam melting, different melting strategies can lead to different material properties. For this purpose, Freemelt has developed software in which these can be used in the same component as required. Examples of this are turbine blades or hip stems in which, for example, elongation is desired at one end and stiffness at the other end. This is achieved through different melting strategies, layer by layer, by choosing between line melting, Bezier melting or point melting.
Speaker/s
Peter Jain Freemelt AB Managing Director Sales
Peter Jain studied mechanical and industrial engineering at the Baden-Wuerttemberg Cooperative State University Stuttgart. He earned his Executive Business Management degree from the University of Bolton. After several years as a managing director in the automotive and machinetool industries, he has been working in the additive industry for many years. His previous positions have included GE Additive and Desktop Metal. Today he represents Freemelt AB as Managing Director Sales.
AM Science
Postprocessing of powderbased additiv manufacturing with parts out of plastic
Prof. Dr.-Ing. Paul Helmut Nebeling // University of Applied Sciences Reutlingen
de
AM Science
Production of additive manufactured parts out of plastics by SLS-method is widely distributed. There are many opportunities which can be realised by that. There is a large freedom in design parameters. The process chain after the buikt process is characterised by manual steps. Also detection of manufacturable features and automated post processing will be cover by this paper. A complete and consistent automated process chain is described.
Speaker/s
Prof. Dr.-Ing. Paul Helmut Nebeling University of Applied Sciences Reutlingen Professor at the University of Applied Sciences Reutlingen