Additive Manufacturing

With the help of additive manufacturing processes, development times can be drastically reduced and highly complex component geometries can be manufactured more cost-effectively. Thanks to the many advantages of tool-free production, additive manufacturing (AM) is being used in more and more industries. While aviation and medical technology were the main drivers until recently, applications in toolmaking, special machine construction and automotive engineering are now increasingly being developed. Fraunhofer IPK supports you in exploiting the potential of these new manufacturing methods for your company. Together we examine your use cases and develop the appropriate processes and technologies.

Our interdisciplinary team is specialized in the metalworking processes Laser Powder Bed Fusion (L-PBF) and Directed Energy Deposition (DED). Among other things, we offer you economical manufacturing solutions for the latest tool concepts, develop customized repair processes and shorten your time-to-market by using simulation tools. The development of new machine concepts for AM to increase the product quality and manufacturing robustness of our customers is another core topic.

Our strength is our broad manufacturing know-how. We combine classical production methods, automation concepts and IoT systems with additive processes in a targeted manner. For us, additive manufacturing is not an end in itself, but a decisive component for solving current challenges in production.

 

Feasibility and profitability analyses

Would you like to implement your ideas quickly and efficiently? With our many years of production engineering experience, you have a highly qualified partner at your side.

 

Tool development

In addition to additive manufacturing itself, we also offer process-oriented design, simulation, component finishing and functional verification of tools in real use.

 

New machine concepts

Whether you want to optimize individual components, design a complete production system or implement a completely new plant concept – we are your development partner.

 

Repair technologies

With feasibility studies, optimized process design and path planning as well as the implementation of repair procedures in existing production chains, we offer a comprehensive range of services for the repair of parts and components.

 

Simulation

We accompany your additive processes with virtual tools and make sure that the construction job works from the very beginning.

 

Quality management

With the help of powder qualification, process design, process monitoring and testing, we realize a continuous quality assurance of additive processes.

Fraunhofer Additive Manufacturing Alliance

As part of the Fraunhofer Additive Manufacturing Alliance, we are affiliated with 19 other Fraunhofer Institutes dealing with the topic of additive manufacturing.

Selected references

Additively manufactured components for measuring devices

3D printing of components for emissivity measurement of semi-transparent materials

Reliable and robust

Together with partners from industry and science we develop quality routines along the additive process chain.

AddiCut

Additive manufacturing of an optimized milling tool

Electrical drives

Can components for electric drives also be produced using 3D printing? We are researching answers to these questions as part of this project at the Werner-von-Siemens Centre for Industry and Science.

High-temperature applications

In this project of the Werner-von-Siemens Centre for Industry and Science we investigate which additive manufacturing systems are suitable for high-temperature components.

Maintenance, repair, overhaul

Upgrade instead of repair: We research how components can not only be repaired but also improved during the service process using additive methods.

Combined process chain

We combine selective laser beam melting and laser powder cladding in one process chain to enable increased functionality of additively manufactured components.

Sensor technology in additive components

3D printing and IoT solutions offer new ways to monitor the condition of safety-critical components.

Blockchain and Industrie 4.0

Exploiting the potential of Blockchain and the Baseline Protocol for additive manufacturing.