Through the research of the DMRC a few innovations have been developed. These innovations appear in different fields of research and are presented in detail here.

Feasibility study on the use of AM for electrical engineering. A special example here is a rotor shaft for a permanent magnet synchronous motor.

Advantages of additive manufacturing using the example of functional integration of damped structures. Application example: armature plate in a spring-loaded brake.

For the production of fine-structured bipolar plates, a suitable manufacturing process was needed. Due to the process characteristics, the FDM process offers many advantages in order to produce suitable tools for the forming process.

Temperature effects in the polymer laser sintering process are an important aspect regarding the process reproducibility and part quality. Depending on the job layout and position within the part cake, individual temperature histories occur during the process.

The layered structure of Additive Manufacturing processes results in a stair-stepping effect of the surface topographies. In general, the impact of this effect strongly depends on the build angle of a surface whereas the overall surface roughness is caused by the resolution of the specifi c AM process. The aim of this work is the prediction of surface quality in dependence of the part building  orientation.

The reduction of process times in additive manufacturing is a major focus of research. The aim of the investigation was to reduce the time, required for a process route, of the additive manufacturing process for the Ti6Al4V titanium alloy with subsequent HIP process. Procedure Therefore, this study pursues comprehensive investigations on the mechanical properties of the titanium alloy TiAl6V4, which was processed in an optimized process chain.

The surfaces of additive components are not as smooth as for conventional machined parts due to the manufacturing process. Therefore, AM manufactured components require a surface post treatment.

More information on a topology optimized and additive manufactured air craft damper bracket in cooperation with H&H.

Technical and economic feasibility study for the use of the SLM process for a hydraulic clamping device. A high weight saving could be achieved by topology optimization.

In this study, together with ESA, the suitability of AM for components on satellites was investigated. The result based on topology optimization is a futuristic-looking component that scores technically and economically in many points.

A design adjustment of the inner structure minimizes the floating overhangs in the range of the flow channels. Due to this adjustment, the use of any kind of support material can be avoided. In this way it can be ensured that no residues of water soluble or non-biocompatible material remain in the system.

In order to save resources and adapt parts better to their requirements, companies are focusing on part optimization for lightweight design. Unfortunately, the existing software for topology optimization is characterized by several shortcomings: Modeling is a lengthy, labor-intensive process,the computing time is long and extensive expertise and manual reworking is required.

Experience from conventional manufacturing shows a good performance of the high-strength aluminum alloy EN AW 7075 which leads to frequent use in automotive and aerospace sector. Scientific investigations on the processability of this alloy in the SLM process shows that prepared samples have anisotropic behavior due to process-induced hot cracks (Figure 1). Furthermore, it was not possible to determine solid results regarding the fracture mechanical characterization.