Öffentlich geförderte Projekte
Metal components and assemblies can be manufactured layer by layer using Additive Manufacturing (AM). The process principles provide both design freedom and new possibilities regarding the material. The aim of this research project is to systematically investigate the potentials of additive manufacturing processes in electrical engineering, especially in rotors of permanent-magnet excited synchronous machines (PMSM). This project is a cooperation between the DMRC and the IAL (Institute for Drive Systems and Power Electronics) of Leibniz University Hannover.
The POLYLINE project brings together 15 industrial and research partners from Germany to develop a next-generation digitized production line. This line will be used to produce plastic components for the automotive industry. The aim is to supplement established production techniques (e.g. machining, casting, etc.) with additive manufacturing (AM) high performance line production systems.
The research project KitkAdd refers to the topic "Additive Manufacturing - Individualized Products, Complex Mass Products, Innovative Materials (ProMat_3D)" and was announced in the announcement of the BMBF on March 27, 2015. The project focuses on individualized products and complex mass products produced by additive manufacturing processes and aims to increase the economics of Selective Laser Melting (SLM) by combining it with established manufacturing processes. In order to achieve this, an interdisciplinary view of the areas of development, design, process chain integration and quality assurance will be focused.
This project is about the ability how to use AM components for forming processes. Innovative rupture discs shall be produced with a high-speed forming process called HGU (German: “Hochgeschwindigkeitsumformung – HGU). The challenge is to ensure a stable application even with small nominal sizes of the rupture discs. A significant innovation is the insertion of predetermined breaking points by secondary features in the forming process. These shall be implemented in a thermoplastic FDM die. Therefore, the development of a tool system with additively manufactured components (die and plunger) is planned for the production of innovative rupture discs. This will combine the advantages of a quasi-static and high-speed forming process in an innovative, efficient and unique tool system.
The overall objective for iBUS was to develop and demonstrate by August 2019 an innovative internet based business model for the sustainable supply of traditional toy and furniture products that is demand driven, manufactured locally and sustainably, meeting all product safety guidelines, within the EU. The iBUS model focuses on the capture, creation and delivery of value for all stakeholders – consumers, suppliers, manufacturers, distributors and retailers.
The aim of this project is to investigate the requirements for materials and semi-finished products which are processed in extrusion deposition 3D printing processes. By gainig a better understanding of these processes, a knowledge base should be created, to increase the variety of materials that are available. This project is conducted in cooperation with Albis Plastic and under the NRW Fortschrittskolleg “Lightweight – Efficient – Mobile” (FK LEM). As one of the six Fortschrittkollegs established in 2014, the FK LEM is sponsored by the Ministry of Culture and Science of the German State of North Rhine-Westphalia.
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.
The properties of additively manufactured, biomedical components made of titanium alloys coated by PVD are investigated. The focus of the investigation is on TiAl6Nb7 (α+β) and TiNb24Zr4Sn8 (β) processed by selective laser melting. Both alloys have the required mechanical properties and corrosion resistance for use as an implant. The mechanical properties, corrosion and fatigue behavior are determinded by means of material analysis and mechanical characterization. The biocompatibility is increased by multilayered or graded coating systems of Ti(Zr,Hf)CN and verified by biological investigations (e.g. cell adhesion, cell culture growth or bio-film formation).
In the transition to a digital and connected industrial production of the future, additive manufacturing offers unique opportunities. The expectations of this group of manufacturing processes are equally high. In order to exploit the diverse potentials, it is necessary to rethink the entire product development process. Special features, such as the possibilities for function integration, must be consistently considered already in the concept and design phase. Within the scope of this project, a catalogue for supporting the conceptual and design tasks associated with function integration by means of additive manufacturing is to be developed and demonstrated specifically in the field of drive technology using application examples.
Since bioresorbable implants are highly interesting for biomedical applications to reduce patient burden, significant efforts are ongoing to develop adjusted metal alloys. Apart from magnesium (Mg) alloys, the iron-manganese (FeMn) system is promising concerning its biocompatibility. Although Mn increases the degradation of Fe, further efforts are necessary to enhance the degradation rate. For example, silver (Ag) phases promote the cathodic dissolution of the matrix material due to their high electrochemical potential. Therefore, the development of new Ag alloys with an adapted degradation profile, are a focal point of this work. Due to the immiscibility of Fe and Ag, it is not possible to cast FeMnAgX alloys, but it is feasible to manufacture these alloys using powder-bed-based additive technologies.
The Arburg Plastic Freeforming (APF) is an additive manufacturing process with which three-dimensional, thermoplastic plastic components can be produced. The components are produced layer by layer through the deposition of fine, molten plastic droplets. The aim of this research project is to determine the potential and process limits of the APF process. The focus is on the mechanical, geometrical and visual properties in correlation to the process parameters. In addition, the wetting behavior of the plastic droplets and the influence of the material degradation due to a possible thermal degradation will be investigated.
The limited choice of materials still portrays the obstacles faced in diverse applications of selective laser sintering process. Most of the products are therefore manufactured using PA12. Currently, there are no suitable methods for the production of powders from other polymers. Within the framework of the EFRE-project, two different powder manufacturing methods shall be adapted and introduced here. The first method describes a cryogenic milling with an aftertreatment involving thermal particle rounding while the second method describes the PGSS process, also known as the high-pressure spray process. Through these production plants, new powders for the laser sintering shall be manufactured in the future.
Laser Beam Melting (LBM) allows not only the cost-effective production of metal components with highly complex geometries, but also the processing of materials that cannot be produced by conventional methods such as casting. The design of new application-adapted alloys therefore enables the manufacture of intelligent products with superior properties as well as the expansion of additive production to new areas of application. The aim of the project is to establish a process chain from alloy design and powder production to material analysis and quality control.
The aim of this project is the successful implementation of additive manufacturing in electrical engineering. In order to introduce and exploit the advantages of additive manufacturing in electrical engineering, innovative application concepts will be identified and investigated. This is achieved by the identification of innovative cooling and lightweight design concepts within engine components. However, the main focus of this project is very interdisciplinary. Therefore, this project is a collaborative project between the DMRC and the IAL (Institute for Drive Systems and Power Electronics) at Leibniz University Hannover, combining the experise of alloy-design, design guidelines and mechanical as well as electrical characterization.
The automotive industry is a key industry in Germany and one of the country’s largest employers. To withstand international competition and meet increasing customer requirements, innovative, flexible and versatile types of production are in demand. Particularly, electric mobility is greatly interested in lightweight and low vibration parts with a high degree of function integration. Additive manufacturing can make a significant contribution towards realizing such requirements. Within this project, a prototype additive series production will be implemented for the automotive industry.
To achieve the performance of conventionally manufactured components, additively manufactured components have to fulfill at least the same requirements. This includes the possibility of functionalized surfaces with coatings and of being able to realize a sufficient fatigue strength of the overall system (component/coating). In the present project, therefore, the effects of residual stress and surface roughness, known as the restriction of the SLM process, on the coatability are fundamentally examined and the dynamic strength of the overall system is considered.
In the project proDruck a holistic employment model for people with disabilities will be developed. Focus is the development and 3D printing of individual technical assistance systems for people with disabilities, which enables help for self-help. With the development of new business models and web-based training concepts, the participation in sustainable technologies and their active co-creation will be possible. A 3D printing workshop is planned, which is adjusted to the specific needs of people with disabilities.
This project is part of the Clean Sky 2 funding program and is carried out in cooperation with other research institutes. Clean Sky 2 is a joint venture through a public-private partnership between the European Commission and the European aviation industry to achieve defined environmental objectives. Environmental goals are, for example, the reduction of CO2, gas emissions and noise level produced by oder of aircrafts. This project aims to develop a novel leading edge concept based on advanced manufacturing and integration techniques.
The Fused Depositioning Modeling (FDM) process is one of the most common additive manufacturing processes. Due to the cooling of the material after the deposition of the thermoplastic strand, shrinkage occurs. The degree of the occurring shrinkage depends on certain process parameters as well as on the geometric properties of the components. As the influences of these process parameters and geometric properties are not yet sufficiently known, this project investigates the effects on the shrinkage by the use of simulations of the ongoing processes inside the FDM machine.
New materials and processes enable saving weight of parts and components and thereby saving energy. To develop and modify materials to make them suitable for additive manufacturing, the Chair of Materials Science (LWK) with the Direct Manufacturing Research Center (DMRC), the Chair of Technical and Macromolecular Chemistry (TMC) and the Competence Center °CALOR as part of Rostock University are cooperating within the Special Priority Program (SPP) 2122, promoted by the German Research Foundation (DFG). Together, they face the challenge to process hard to weld materials like high-strength aluminum alloys by using powder bed-based laser beam melting (PBF-LB/M). One approach in this project is the modification of initial state powder with nano-size particles.