Additive Beats Conventional

What is the focus of your research right now?

Neuwald: 

We are researching the use of powder bed technologies along the entire additive value chain. Here we investigate questions such as: Where are the limits when processing materials that are difficult to weld? What will the production systems of the future look like? What needs to be done to the components after printing? And how can I avoid having to do a 100 percent CT-inspection in safety-critical applications such as aviation, medical technology or the energy sector?

Biegler:

We stay close to the process: How do I apply certain materials? How do I design the process to robustly achieve high quality results? We mainly investigate these questions for DED processes. We also support companies in the selection of use cases: Where is using additive manufacturing technologies economical?

And where is that the case?

Biegler:

When repairing very large and expensive tools in car body manufacturing or forging operations. In these cases, existing damaged areas are removed and then manually restored by a welder. We have automated these manual steps. When additive technologies become cheaper, they will also become interesting for the repair of components that only cost 1,000 and not 20,000 euros.

Neuwald: 

Burner heads for energy production are already being manufactured additively today. The advantage here is that I can consolidate the production of individual components and their assembly and adjustment into a single part and create more complex geometries that improve the combustion. This approach adds value that the chemical and process industry will also benefit from in the coming years.

Why are simulations important?

Biegler: 

Because the processes are so complicated. Trial and error is too costly here. With simulation processes, we can explore our parameter window without taking up any machine hours and perhaps achieve First Time Right directly.

Neuwald: 

Additionally, components deform during the process. That is why we are working on simulation tools that also offer a reliable distortion simulation so that we can properly compensate the components in advance.