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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
Powder particles are used as raw material for laser-based additive manufacturing 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)

Powder particles are used as raw material for laser-based additive manufacturing

OptiAMix – Multi-target-optimized product design für additive manufacturing

The overall objective for OptiAMix is to develop various methods and tools for the introduction and use of additive manufacturing in the industrial environment. These include the development of a software for automated and multi-target-optimized component design, methods for the strategic-technical component selection, the derivation of design rules and component identification as well as a general integration methodology for additive manufacturing into companies.

General Situation
Due to high design freedoms, additive manufacturing processes are gaining increasing interest in industry and research. For example, the VDI confirms that the technology is of outstanding importance for Germany as a business location: additive manufacturing processes promote the implementation of the Industry 4.0 strategy, secure jobs, shorten transport routes and offer opportunities for new business models. At the same time, the industrial applicability of additive manufacturing processes has so far been rather low due to various limiting factors. For the industrial application of AM knowledge within the strategic product planning, software for AM-compliant design as well as methods for interdisciplinary cooperation in product development, which take a holistic view from the idea to the products as well as the entire process, are missing.

Multi-target optimized component design

Solutions within OptiAMix
Addressing these problems, the aim of the project "OptiAMix" is the multi-target-optimized and fully automated component development for additive manufacturing processes throughout the product development process. In order to be able to carry out a multi-target optimization with regard to diverging factors, such as low costs or a load-oriented design, a new software tool is developed for AM-compliant design in terms of technology, post processing, load and cost and combined with known software tools. Thus, the increasing product complexity can be mastered and a high level of data security can be guaranteed. At the same time, methods will be developed and consolidated to generate and use the relevant information; these include, for example, the potential estimation of additive manufacturing processes, design guidelines as well as process and material parameters, which are needed for the requirement-oriented, automated design and thus considerably shorten the design time. The process chain itself is also considered within OptiAMix, a standardized and optimized solution is developed together with the project partners, and a methodology for the integration of additive manufacturing into the existing processes of the companies is developed.

Latest results
In the first year of the project, promising progress has been achieved in all the sub-objectives of the project. In the sub-goal "Method for strategic-technical part selection", the researchers of the C.I.K. developed the already existing trade-off methodology for cross-industry application. The branches automotive, food technology and plant and mechanical engineering represented in the project were focused on this objective.

In the target areas "Method for the derivation of design rules" and "Tool for automated and multi-target optimized component design", the chairs KAt, LiA and CIK first developed, produced and tested resilient test specimens for the development of design guidelines for the areas load, post processing, cost and production. From this design guidelines were derived, which will serve as the basis of the optimization tool. The KAt researchers implemented the first guidelines as machine-readable forms in a database, which the tool developed by INTES will later access.

Test specimens for the development of design guidelines

In the development of a methodology for the "Integration of additive manufacturing in companies", the product development processes of all project partners were analyzed and partially optimized. From this, an "ideal AM process" was derived, which in the future should serve as a component in the field of process integration. Already integrated in this process are the results from the "Method for strategic-technical part selection" as well as the "Method for Part Marking".

Test specimens for component marking

Outlook
The next 1 ½ years of the project will be used to fully develop the tool for automated and multi-target optimized component design and to finalize the method for the integration of additive manufacturing in companies. In addition to the various sub-goals, different support tools will be created for manufacturing documentation as well as for accompanying the product development.

Further project information
Duration 01/2017 – 12/2019
Partner UPB (C.I.K.; KAt; LiA; HNI-PE), Krause DiMaTec GmbH, EDAG Engineering GmbH, INTES GmbH, Hirschvogel Umformtechnik GmbH, WP Kemper GmbH
Supported by BMBF - Federal Ministry of Education and Research
PTKA - Projektträger Karlsruhe (Project Management Agency Karlsruhe)
Research leader Prof. Dr.-Ing. Rainer Koch (CIK)
Prof. Dr.-Ing. Iris Gräßler (HNI-PE)
Prof. Dr.-Ing. Detmar Zimmer (KAt)
Prof. Dr.-Ing. Thomas Tröster (LiA)
Research assistants
 
Stefan Lammers, M.Sc. (KAt)
Johannes Tominski, M.Sc. (KAt)
Dipl.-Ing. Ulrich Jahnke
Anne Kruse, M.Sc.
Thomas Reiher, M.Sc.
Stefan Lammers, M.Sc.
Johannes Tominski, M.Sc.
Jan Gierse, M.Sc.
Philipp Scholle, M.Sc.
Christian Oleff, M.Sc

Funded by

Federal Ministry of Education and Research

Assisted by

Projektträger Karlsruhe

Contact

Prof. Dr. Rainer Koch

Computeranwendung und Integration in Konstruktion und Planung

Rainer Koch
Phone:
+49 5251 60-2258
Fax:
+49 5251 60-3482
Office:
P1.3.19

Stefan M.Sc. Lammers

DMRC

Design technology (drive technology)

Stefan Lammers
Phone:
+49 5251 60-5472
Office:
W2.103
Web:

Johannes Büsching, M.Sc.

DMRC

Ramp-Up Management for Additive Manufacturing

Johannes Büsching
Phone:
+49 5251 60-5473
Office:
P5.2.02.2

Phone:
+49 5251 60-5542
Fax:
+49 5251 60-5409
Office:
W 2.201
Web:

M.Sc. RWTH Philipp Scholle

DMRC

Strategic Planning and Innovation Management

Philipp Scholle
Phone:
+49 5251 60-6263
Office:
F0.306

Christian Oleff, M.Sc.

DMRC

Systems Engineering, Strategic Planning & Innovation Management

Christian Oleff
Phone:
+49 5251 60-6256
Fax:
+49 5251 60-6280
Office:
F0.306

M.Sc. Johannes Tominski

DMRC

Design technology (design rules)

Johannes Tominski
Phone:
+49 5251 60-2289
Fax:
+49 5251 60-3206
Office:
P1.2.10.3
Web:

Thomas Reiher, M.Sc.

DMRC

Part design optimization

Thomas Reiher
Phone:
+49 5251 60-2263
Fax:
+49 5251 60-3482
Office:
P1.3.24

Anne Kruse, M.Sc.

DMRC

Technology Implementation in existing production processes

Anne Kruse
Phone:
+49 5251 60-2296
Fax:
+49 5251 60-3206
Office:
P1.3.16

Dipl.-Ing. Ulrich Jahnke

DMRC

Lifecycle Costs, Intellectual Property Rights and Prevention of Product Piracy

Ulrich Jahnke
Phone:
+49 5251 60-2290
Fax:
+49 5251 60-3482
Office:
P5.2.02.2
Web:

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