Conference Programme of Rapid.Tech 3D - 2022

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.

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.

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.

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 

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

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.

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.

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

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)

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.

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

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. 

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 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.

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. 

Speaker/s

Julian Ulrich Weber
IAPT
Research Associate

Professional experience

• Research associate, PhD student, Fraunhofer IAPT, Hamburg — 05/2019 - today
• 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
 

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

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.

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!

Speaker/s

Benedikt Ebner
Sales Executive EMEA 
Oqton Inc. – Additive Manufacturing Software

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.

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.
 

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 

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

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".

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-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

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.

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

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.

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. 

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.

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

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

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

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.

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.

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)
• Karl Späh GmbH & Co. KG: Management / Coordination Additive Manufacturing (from 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.

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! 

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

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

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

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

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.

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.

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)”

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

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)

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.

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
• 08/2004 – 07/2013 Higher Education Entrance Qualification
  Gymnasium „In den Filder Benden“, Moers

Professional Career

• 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

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

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

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
• 09/05-09/10    MTM, Katholieke Universiteit Leuven, Belgien
• 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

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
• 2014 GKD – Gebr. Kufferrath, Düren: four-week internship
• 2017 SMS Group, Belo Horizonte (Brasilien): three-month internship
• 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“

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

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.

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
• 2011 - 2011 7 month temporary employment abroad (USA)
• 2011 - today Götz Maschinenbau GmbH & Co.KG
• 2013 chief erector
• 2014 adding Aditive Manufacturing
• 2017 Quality manager
• up to today CEO

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

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

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

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
• Fachhochschule Darmstadt Fachbereich Maschinenbau - Fertigungstechnik, Germany 
  Diplom Ingenieur (Degree in Mechanical Engineering); 1994

Professional Development

• Personal Coaching, Certified Coach Jerry Houston
• International Management Development, Management Center - St, Gallen, Switzerland
• Syntegration® Seminar - Management Center - St, Gallen,  Switzerland
• Numerous German and American Management Development Seminars, Heraeus, Inc.
• Executive Speaking and Presentation Skills Seminars, American Management Assoc.
• Planning and Developing New Products and Markets Training, Heraeus, Inc.
• Leader Effectiveness Training, Houston and Associates
• Selling on Technology Seminar, Heraeus, Inc.
• Active Participation in Achievement of QS 9000 Certification, Heraeus, Inc.
• Leader Effectiveness Training, Heraeus, Inc.
• Continuous Improvement, Problem Solving Tools, Statistical Process Control, Project Management Tools and Software Classes; worldwide
• Practical Training, Technical Processing/Machining Techniques, Gebr. Knauf Westdeutsche Gipswerke, Germany; 1989-1990
• Technical Training, Engineering/Manufacturing Techniques, Schulwerkstatt Metall, Germany; 1986-1987

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.

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

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
 

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. 

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.

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.

Speaker/s

Dr.-Ing. Matthias Fischer
BASF 3D Printing Solutions GmbH
Application Technology Manager 3D-Material Extrusion

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.

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.

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

Education/Study

• 1973 - 1977 Ludwig-Erk-Grundschule, Wetzlar
• 1977 - 1983 Freiherr-vom-Stein-Schule, Wetzlar
• 1983 - 1986 Goethe-Schule, Wetzlar
• 1986 - 1987 Grundwehrdienst, Instandsetzungsbatallion 5, Wetzlar
• 1987 - 1992 study mechanical engineering, RWTH Aachen, graduation Diplom-Ingenieur

Beruflicher Werdegang

• 1992 – 1997 research assistant WZL RWTH Aachen dissertation in the field of dynamic behaviour of machine tools (chair of Prof. Weck)
• 1997 - 2001 project engineer development Fa. EMAG, Salach
• 2001 - 2005 design manager, Witzig + Frank GmbH, Offenburg
• 2005 - Dez. 2009 manager design and development, Walter Maschinenbau GmbH,Tübingen

Current occupation:

• since 2010 chair machine tools, production equipment, controls, additive manufacturing at Reutlingen University