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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Partner of the DMRC Show image information
Partner 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.

Partner of the DMRC

Partner 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

Funding cycle 2018

The current funding period 2018 allows the funding of 8 research projects, which results are exclusively available to DMRC industrial companies. Some projects have emerged from previous projects so that new knowledge can be deepened.

Additive manufacturing of medium carbon steels and a CoCr-alloy

Since a decade, selective laser melting (SLM) has gained significant attention from academia and industry. This powder-bed based technology enables the manufacturing of highly complex and filigree parts in a near-net-shape manner with a relative density of approximately 99.9 %. However, the  material spectrum available for SLM must be extended in order to further industrialize the process. So far, almost all research has addressed austenitic-, precipitation hardenable stainless-, maraging-, and martensitic steels.

Benchmark of Meltpool-Monitoring equipment for processing 316L

In order to assure quality of SLM manufactured parts, a view into the production history of each layer might help to increase trust in this procedure and help to minimize post-process quality costs.

Changes of stainless steel powder

There is high market potential for the production of metal parts using Additive Manufacturing (AM) technologies: In many applications, stainless steel (1.4404) with a good corrosion resistance is widely used. For example, in the field of passenger services or goods traffic with trains, or the automotive industry there are many applications, which can be produced cost-efficient by AM, e.g. brackets, hydraulic components. For serial production, deep knowledge on the robustness of part properties against variation of powder characteristics is required.

Concept and case studies 2018

Additive Manufacturing (AM) is a technology that can be used to increase the function and efficiency of designs. One of the limiting factors in adoption are design studies with relevant empirical data that show performance enhancements. The idea of this project is to develop generic design studies that are relevant to the members´ application needs, run analysis, collect performance data and report the benefits. Thus, the project idea is adapted year by year with facing new challenges or harnessing further potentials of AM.

FOCUS – Active Strategy Implementation and Advancement

Still there is a challenge to envisage future evolutions of AM and to provide valid fundaments for strategic decisions within enterprises and business units. Requests indicate that the five public DMRC studies still attract significant interest for the DMRC. As an “Industrial Research Base”, the DMRC needs to act as an influencer in the community, to focus ambitions towards key research areas, to advance quickly but sound in all of these areas and strengthen strategic decisions of partners. DMRC needs to actively drive growth (regarding academic chairs and industry partners), community interactions (EU, AM Platform, IMS, VDI, VDMA, Bitkom) and relationships (based on DynAMiCS results) with a clear and continuously updated focus.

High Temp Applications – Potentials of PA613

Within the last DMRC Project “LS Polyamide for High Temperature Applications – Processing and Properties of PA613” it could be shown that the new LS material PA613, delivered by Evonik, shows good processability on the regular “low temperature” LS EOS P396 machine and mechanical part properties are about 25 % better than the ones of polyamide 12 build parts. However, beside higher strength, higher temperature resistance is required in advanced applications like electronics or automotive industry. The temperature resistance in addition to other advanced short term material properties will be investigated within this project. As PA613 is not known in conventional manufacturing it is important to classify the material within the range of engineering plastics to become a new high performance material in industry, for this purpose more information about part properties have to be generated.

Processing of alternative FDM materials

Not many high performance polymers are available for AM processes. A widespread manufacturing process is the Fused Deposition Modeling (FDM). In the FDM process, the semi-finished product is a thermoplastic polymer filament. In a FDM head the filament is melted and forced through a heated nozzle. A layer is generated by the movement of the head along the x- and y-axis and the simultaneous extrusion of melted polymer. By the deposition of various layers, three-dimensional components can be produced.

Qualification of Laser Sintering Serial Production

The superior motivation of the project “qualification of serial production by laser sintering” is to enhance laser sintering more and more to a serial production process. LS has many factors which can influence the process like shown in figure 1. It is essential for a serial production process to achieve high accuracy as well as reproducibility and actually there is no general qualification procedure and quality management concept for LS serial production to handle these influencing factors in a common way. Presently, the users of LS machines, and in particular unexperienced users, need to develop their own internal qualification procedure to decide whether a serial production of a concrete part is possible or not and they also need to develop a quality management concept to build quality parts for their customers continuously.

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