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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Industry partners of the DMRC. Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC. Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part. Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites. Show image information
Employees of the DMRC working with the "freeformer" from Arburg. Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM). Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Industry partners of the DMRC.

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC.

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part.

Additive manufactured reaction wheel bracket for telecomunication satellites.

Employees of the DMRC working with the "freeformer" from Arburg.

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM).

Involved Chairs

C.I.K. - Chair for Computer Application and Integration in Design and Planning

The research group Computer Application and Integration in Design and Planning (C.I.K.) takes advantage of basic technologies and innovative IT concepts and technologies together with the related methodologies. Specific research and work priorities are:

  • Analysis of requirements in close cooperation with stakeholders based on the adaption and advancement of approved requirement engineering methods.
  • Application of software engineering methods from conceptual design to implementation of information systems.
  • Evaluation of research results and quality management in the product development with focus on usability of software solutions.

In collaborative research projects the C.I.K. bridges the gap between science, industry and user. This is emphasized by close connections with manufacturing and
service companies including small and medium sized enterprises as well as large industry. The focus on problems and goals of human stakeholders supports the transfer of research results into practice. In the context of decision support and expert systems as well as knowledge based approaches and information management various methods are applied and scientifically analysed. The IT-based collection, processing and target oriented provision of information is studied with respect to pragmatic aspects. In this regard, the use of business process management methods and semantic technologies is a major priority in current projects. The projects of the C.I.K. cover a broad spectrum of relevant topics in the field of Design and Planning. Specific goals are given by the collection of experiences, the integration of expert knowledge into product and process models, the identification and utilization of hidden knowledge as well as IT support in complex environments. The research group C.I.K. is one of the leading German institutes for research on civil safety and security. Within numerous projects the research group is building the bridge between civil rescue organisations, additional end user groups and other project partners. The experience in industry research has been enhanced with the beginning of scientific projects in the field of Additive Manufacturing. The C.I.K. is currently attracting international attention with the coordination of the EU funded project “RepAir” and the ESA project “New Structure”. The gained expertise is the foundation for our ideas, systems and technologies in the context of emergency planning, coordination support, training and decision support. Today thirteen research assistants and about twenty student assistants are working for the C.I.K. bringing in knowledge from the fields of engineering, computer science, economics and mathematics.

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FAM - Institute of Applied Mechanics

Teaching and training

During the lectures of the institute for applied mechanics, basic knowledge and procedures to assess stress conditions and the course of movements of components
as well as of machines is imparted. Model design, which identifies the process of transferring real components into abstract models for calculation purposes, plays an important role. During the undergraduate study period the courses are characterized by the imparting of basic knowledge concerning technical mechanics (static, strength theory, dynamics) while during the advanced study period basic research and practically oriented knowledge is consolidated especially with respect to strength optimized and fracture save design, methods of structure analysis, the Finite-Element Method, computer supported product optimization and biomechanics.

Research

The FAM conducts application oriented and pure research and development in the area of applied mechanics. The motivation essentially arises from the areas of structural mechanics, biomechanics and computer simulation and may be divided into three main research fields. “Strength optimized and rupture safe design of components” deals with the dimensioning and optimization of components and structures with respect to the practically oriented development of the existing Finite-Element-Method standard software and its efficient use in various applications. In this connection the applied tools are stress and deformation analysis as well as notch stress tests and fracture mechanical tests including fatigue crack growth experiments. The extension behavior of fatigue cracks in many cases determines the life time of the components and technical structures. To predict the crack growth behavior and to prevent damage, various crack growth simulation programs were created and are in use at the institute. The area “Biomechanical analysis of the human motor activity” covers the designing of the human bone structure with the help of computers over the simulation of courses of movement up to the optimization of implants and prosthesis and the development of intelligent healing aids. The aims are the evaluation of injury risks, the avoiding of resulting injuries and the optimized use of prostheses and implants. The third area of research “Optimization and new development of products in cooperation with industrial partners” deals with the solving of concrete problems
which occur in practice by implementing the above mentioned core competences.


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HNI - Chair for Product Creation

The chair’s field of action spans from planning business strategy to the produced product. Within strategy planning and innovation management, promising
product ideas are generated by systematically forecasting markets, technologies and business periphery. In addition, strategic business segments are planned and creativity techniques are applied. Strategy planning is triggered either by the market or by new technologies.

Additive Manufacturing is an impressive example of product technology push as
well as production technology push. On the one hand, new business chances result from innovative core products, characterized for example by outstanding material properties or 3-dimensional geometries which cannot be manufactured by conventional dissipating production technologies, such as milling or turning. On the other hand, new services can be offered, such as provision with a component’s 3D geometry for end production at the customer’s 3D-printer. Therefore, we support companies in identifying and measuring their specific potential of using additive manufacturing as product or production technology.

In case of a sufficient potential of Additive Manufacturing for a specific business segment at a company, we support strategic orientation, product program planning, engineering methodology, production planning and implementation of additive manufacturing. Engineering methodology provides tools and methods of functional realization of the product. Virtual and Augmented reality is used as an enabler. Early consideration of production constraints, such as production site or degree of automation, is supported by integrated production management.

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KAt - Chair for design and drive technology

The focus of our work lies on theoretical and experimental investigations regarding drive conceptions and on the extensions of drives’ application limits. Thereby, key aspects are:

  • the reduction of the resources needed for the operation of drive systems, and
  • the modularity of drive systems in the context of an intelligent variant management.

The optimization of components, assemblies and machines by:

  • systematic, function-oriented and production-oriented design is another area

of work of our chair. Thereby, an important aspect forms the

  • tolerance management.

Regardless of the task field, we often work with industry partners on joint projects. Primarily, we deal with

  • drive systems, such as „energy-efficient spring-applied brakes“, „self-optimizing air gap adjustment“, „multi-drive concepts“, „modular drive systems“
  • drive components, such as „power loss reduced sealing systems“, „reduction of fretting corrosion“ and
  • design technology, such as „development of design rules for additive manufactured parts“ and „tolerance management“.

For our work we usually use software tools to create geometry (CAD), for modeling and calculating the motion behavior (multi-body simulation). In parallel, we develop and use test equipment to conduct experimental studies. In teaching, we offer courses on the following topics:

  • • Basic bachelor studies: Technical drawing, machine elements - fundamentals, machine elements - joints, machine elements – drive components, design drafts.
  • • Deepening bachelor and master studies: Methodology of design, technical design, industrial drives and geometrical tolerancing.

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KTP - Chair for polymer processing

The KTP stands for thirty years of successful research and development of manufacturing processes in the field of polymers and rubbers. This results in a qualified training in the theoretical and practical field of polymer engineering as well as in an intensive cooperation with regional, national and international industrial companies. International congresses and conferences are regularly participated by the KTP staff. The KTP belongs to the faculty of engineering at the University of Paderborn and its two professorships ensure a broad range of knowledge transfer.

  • Polymer Engineering, Prof. Dr.-Ing. Elmar Moritzer
  • Polymer Processing, Prof. Dr.-Ing. Volker Schöppner

The research at the KTP is about different kinds of polymers as innovative solid material, the potential of which is by far not exhausted. Polymers become more and more significant in the field of mechanical engineering, above all in the automobile industry, and displace traditional materials in their application fields. To adapt the processing performances optimally to the technical requirements, the KTP has developed application-oriented simulation tools for all fields of polymer processing. These software tools help to find solutions of problems quickly and make it possible to achieve a high process transparency. The research foci have a special concentration on the transformation of process models, which have been built on the basis of process analyses (experimentally or theoretically), into tools to simulate polymer processing procedures. The central
aim is the simulation of the process chain from the molecule to the end product. Due to the experimental verification of the models and simulation tools as well as in return the use of simulation tools to improve the processes, an interplay between theory, experiment and modeling/simulation in terms of a continuous improving process exists. To realize this strongly feedback-oriented proceeding, real processes in the laboratory- and production measure – the latter often in cooperation with industrial partners – are of the same importance as the theoretical and simulation-based analysis of the processes and the necessary IT- equipment and competence. Hence, the KTP emphasizes a good laboratory equipment.

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LiA - Chair of automotive lightweight construction

-Endowed chair by Benteler AG since 2007-

Research Activities

Due to exhaustible raw materials and demands on climate protection, the reduction of vehicle masses in order to reduce fuel consumption is of critical importance. Therefore, main focus of the group “Automotive Lightweight Construction” is on innovative solutions for the automotive industry and related others in terms of materials, processes and applications. As the economic effi ciency is a critical issue for most industries, the cost structures of different process-routes are also taken into account in order to develop innovative components and applications, featuring high performances as well as balanced cost-to-weight ratios. For example, load-bearing components made of ultra-high-strength steel processed by the press-hardening technique could be mentioned here. Another important research fi eld pursued by this chair is the development of load adapted parts. Within these parts, the material properties in different sections of a component are adjusted depending on specifi c product-requirements, e.g. the mechanical loading. Thus, low or high strengths as well as brittle or ductile areas can be locally tailored by an appropriate selection of the applied process-route. Techniques used in this area are for example the inductive heating, whereby the evolution
of the microstructure as well as physical properties can be modifi ed within a short period of time.
Furthermore, the research focus is on materials and process fundamentals for the development and manufacturing of hybrid-components. Here, different materials, e.g. metals and fi ber-reinforced plastics, are combined and processed in order to allow for a symbiotically usage of the specifi c advantages of each material.

Equipment

Regarding the technical equipment, the chair provides different possibilities for studying material as well as component properties. This covers a wide range of static, cyclic and dynamic tests as well as microstructural studies. In addition to 3 axle tests with static and cyclic forces up to 80 kN, cupping tests with temperatures up to 800 °C can also be performed. Crash tests can be performed with impact velocities of up to 25 m/s and impact energies up to 31 kJ, whereby this test facility can be equipped with an a high speed 3D camera system in order to analyze, for example, local strain distributions. Furthermore, the group of Automotive Lightweight Constructions has licenses of
the major CAD and simulation tools, such as SolidWorks, Abaqus, LS-Dyna and Hyperworks.

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LWK - Chair for materials science

As the majority of innovations is based on the development of new materials or on enhancements of materials already used, the field of materials science is one of th
key activities of today´s research in academia and industry. Under the impact of the increasingly scarce resources the efficient use of materials is the central theme for actual developments. Different strategies can be observed in order to improve the energy consumption of moving parts as well as the overall material amount used in any kind of construction. Depending on the actual requirements in the application the research efforts aim at improving the specific strength or ductility of
the materials (light-weight concept) or at integration of additional functions to the materials, as for example can be observed in case of shape-memory alloys. Other approaches comprise the combination of different materials in order to obtain completely new properties or the enhancement of the material behavior through an optimized microstructural design by advanced proce ssing techniques.

Consequently, the major objective of research at the chair of materials science is to develop validated material models, which allow for predicting the behavior of materials and components under actual loading conditions. In the experiments the stress-strain response and damage evolution of various materials under superimposed mechanical, corrosive and thermal loading conditions is studied. Most of the materials tested are high-performance metallic engineering alloys.

The research projects cover following subject areas:

  • Production of aluminum-steel clad strips by means of twin-roll casting
  • High temperature fatigue behavior of nickel based superalloys
  • High temperature shape memory alloys
  • Microstructural investigations of aluminum and copper wire bonds
  • Optimization of materials processed by selective laser melting
  • Heat treatment of high strength steels for the production of hybrid metal structures with tapered properties and its microstructural characterization
  • Development of new materials for additive manufacturing
  • Intrinsic manufacturing of hybrid structural components in a modified RTM-process

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PVT - Chair for Particle Technology

Particle technology is a specialization in Process Engineering. We investigate the properties of particulate systems; the production, conditioning and manipulation of particulate systems as well as their characterization. Such particulate systems may consist either of solid, liquid (i.e. droplets) or even gaseous (i.e. bubbles) particles in a matrix which might be either gaseous or liquid. These systems show a complex behavior, sometimes called the ‚fourth state of aggregation‘. Particularly, if particles become smaller and smaller particle-particle interactions become dominant for the behavior of such systems. The Particle Technology Group is involved in both fundamental and applied research in the field of particle technology. We have a strong focus on understanding the behavior of particulate systems and to learn how to produce a requested particulate product property. Therefore, doing fundamental, publicly funded research is considered to be equally important as cooperations with companies on very specific projects to develop solutions in the field of particle technology. The Particle Technology Group performs research and offers expertise in the following fields:

Particle synthesis

  • Aerosol particle formation
  • Precipitation / crystallization in liquids

Characterization of particles and dispersed systems

  • Analysis of particle size distribution and particle structure
  • Analysis of powder properties, e.g. bulk flow properties, bulk density
  • Rheology of suspensions
  • Analysis of multi-phase flows, e.g. measuring velocity fields

Handling and manipulation of particulate systems and products

  • Production of composite materials
  • Filtration and separation
  • Dispersion and mixing technology
  • Interface phenomena and nano-particulate systems

Simulation of particulate systems

  • Particle level (e.g. simulation of evolution of particle properties)
  • Unit operation level (e.g. Computational Fluid Dynamics, Population Balance Modeling)
  • Process level (e.g. flow-sheet simulation of complete particulate processes)

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TMC - Chair for Technical and Macromolecular Chemistry

The chair of Technical and Macromolecular Chemistry TMC leaded by Prof. Dr.-Ing. Guido Grundmeier is organized into three research fields namely

  • Interface Science and Adhesion
  • Surface Technology and Corrosion
  • Nanobiomaterials

Structures, forces and processes at interfaces are of utmost importance for materials development in various technological fields. Examples of modern applications of interface-dominated materials are polymer/metal composites, biomaterials, particle technology or energy conversion. Researchers at the TMC are developing new analytical methods and surface technologies in the fields of

  • in-situ analysis of interfacial processes (e.g. adsorption, desorption, self-organization, corrosion),
  • analysis of molecular interfacial forces and mechanics,
  • coating and adhesive bonding of metals and polymers,
  • biomaterials and biosensors

The interdisciplinary work is combining spectroscopy, microscopy and electrochemistry. Molecular defined systems are investigated by optical in-situ spectroscopy,
electron spectroscopy, atomic force microscopy as well as electrochemistry regarding their structure-property-correlation. Based on the special research approach we are on the one hand able to understand macroscopic processes on a molecular level and on the other hand to create new materials and composited bottom- up.

The new research field “Nanobiomaterials” is focused on DNA-nanotechnology and bio-surface interactions. The DNA origami technique enables the fast, high-yield synthesis of well-defined nanostructures which we employ to study biochemical reactions at a single-molecule level. Furthermore, these structures can be functionalized with various organic and inorganic entities for applications in molecular electronics and sensing. The second topic investigates the influence of physicochemical surface properties and in particular surface topography on the adsorption and specific immobilization of medically relevant proteins, and the resulting effects on cellular response, with the aim of improving biocompatibility of implant materials. The TMC teaches students studying chemistry, chemical engineering and mechanical engineering in the fields of Technical Chemistry, Interface Chemistry, Interface Analysis, Electrochemistry and Functional Materials.

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Involved chairs

The University for the Information Society