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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
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.

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).

Internal projects

Internal projects are initiated, steered and performed within a very close cooperation with the DMRC’s industry partners. Also, the industry partners fund internal projects and benefit the most of its results.

Additive Manufactured Function Integrated Damping Structures

Integration of damping functions into existing components via additive manufacturing processes.

Development of an Additive Manufacturing Potential Check System

The project DynAMiCS aims at developing an adaptive check system in order to check for (1) broad potentials, (2) products and services and (3) business models related to Additive Manufacturing. The goal is enabling the DMRC to convey its competences to the industry in a pragmatic fashion. In the context of this project, the fifth sequel of the study “Thinking Ahead the Future of Additive Manufacturing” is going to be composed.

Dimensional Tolerances for Additive Manufacturing

The project “Dimensional Tolerances for Additive Manufacturing” (DT-AM) has two different aims. The first aim is the systematically determination of dimensional tolerances that can be stated if the processes Laser Sintering, Laser Melting and Fused Deposition Modeling are workshop-commonly used. Secondly, relevant process parameters and manufacturing influences will be optimized in order to reduce dimensional deviations.

Direct Manufacturing Design Rules 2.0

The project Direct Manufacturing Design Rules 2.0 (DMDR2.0) has the aim to extend the range of validity for design rules that have been developed previously. Therefore, it will be investigated if and how far the design rules are applicable for different boundary conditions given by different materials, parameters and machines. The additive manufacturing processes laser sintering, laser melting and fused deposition modeling will be considered.

Fatigue Behavior of FDM and LS Parts

The application of additive manufactured end-use parts requires detailed information regarding mechanical properties, e.g., static strength properties. In many applications, changing load conditions occur, so components burdened not only static but increasingly dynamic. In this project, dynamical values of LS parts build with PA 12 as well as FDM parts build with Ultem 1010 and Ultem 9085 will be carried out. Additionally, the creep behavior of FDM parts will be analyzed.

Fatigue Life Manipulation

The main goal of the project “Fatigue Life Manipulation” is to extend the total life time of components. Using intrinsic advantages of additive manufacturing processes, notched parts will be produced in order to manipulate the fatigue life. It is expected that due to changes in stress distribution caused by the notch forms, notch sizes and notch orientations the crack growth behavior will be influenced.

Light-weight construction: Robust simulation of complex loaded cellular structures

A robust Finite Element Analysis (FEA) model for complex loaded cellular light-weight structures will be the aim of the present project. Based on the findings of a preliminary linear elastic simulation the examinations will be extended to linear-plastic deformation behavior including several materials e.g. 316L stainless steel (ductile) and Ti-6Al-4V alloy (brittle). The cellular structures tested will be manufactured by Laser Sintering (LS) in order to verify the developed FEA model.

Surface Topography Analysis and Enhancement of Laser Sintered Parts

To quantitatively assess the surface quality of laser sintered parts a reliable characterization method will be developed. This method serves as analyzing tool for the surface quality of laser sintered parts depending on different machine parameters in order to describe the correlation between machine settings and surface quality. Further work will cover post processing methods to improve the surface finish with reasonable effort in terms of costs and labor.

TPE-A Laser Sintering Material and Part Properties

This project examines PrimePart ST, a polyamide-based thermoplastic elastomer (TPE-A). Unlike established laser sintering materials, this new material is very elastic. This project aims at examining various material and part properties to help with its qualification for future application.

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