Hybrid Materials and Additive Manufacturing Processes (HyMaPro)


In the practical insight sessions additive manufacturing devices for multimaterial approaches are shown in operation.

Every participant can attend 7 of the 14 practical insight sessions focusing on additive manufacturing devices for different materials (M = at Fraunhofer IWS, C = at Fraunhofer IKTS or I = at Fraunhofer IFAM).

Please find detailed session descriptions at the bottom of this page.

In the registration form you can plan your individual lab tour by choosing 7 practical insight sessions.

December 11, 2019

09:00 Welcome
Prof. Alexander Michaelis (Institute Director of Fraunhofer IKTS)
Prof. Christoph Leyens (Institute Director of Fraunhofer IWS)
09:20 Introduction – workshop rules
09:30 Additive manufacturing of ceramic components
(Dr. Tassilo Moritz, Fraunhofer IKTS)
10:00 Enhanced production feasibilities using metal additive manufacturing
(Prof. Frank Brückner, Fraunhofer IWS)
10:30 Coffee break
10:45 Practical insight (choose 2 practical insight sessions)
12:15 Lunch break
13:00 Additively manufactured aerospace and space parts
(Mirko Riede, Fraunhofer IWS)
13:30 Functionalization of components
(Dr. Uwe Partsch, Fraunhofer IKTS)
14:00 Practical insight (choose 2 practical insight sessions)
15:30 Coffee break
16:00 Speed dating
17:30 Get together at Fraunhofer Additive Manufacturing Center

December 12, 2019

8:30 Resent achievements in (metal) printing technologies
(Lukas Stepien, Fraunhofer IWS)
9:00 Simulation for ceramic AM
Dr. Wieland Beckert, Dr. Peter Neumeister (Fraunhofer IKTS)
9:30 Coffee break
10:00 Practical insight (choose 3 practical insight sessions)
12:15 Lunch break
13:00 Wrap-up
Dr. Tassilo Moritz (Fraunhofer IKTS)
Prof. Frank Brückner (Fraunhofer IWS)


Practical insight sessions

M1: Metal Binder Jetting
A brief introduction to the unique features of Metal Binder Jetting will be given. Further the complete process chain and necessary equipment (including printing, hardening, powder removal, and sintering) will be shown. A live demonstration of the printing process will be given.  Major process parameters will be discussed.
M2: Non-destructive testing (NDT) To prove the quality of manufactured components, Fraunhofer IWS uses different non-destructive testing methods. The principles, possibilities, challenges and restrictions of non-destructive testing with focus on optical and X-ray scanning will be presented and can be experienced live at the laboratory. In addition, the process of reverse engineering will be thematised.
M3: Dispense Jetting The integration of dispenser printed conductive tracks onto 3D printed parts will be demonstrated. The process-specific build job preparation, the printing and post treatment will be discussed. The participants will learn about this hybrid process and can assess afterwards potential fields of applications. 
M4: Laser metal deposition with wire
After a brief introduction on the general principle of the process the set up of the process head will be outlined and demonstrate the 5-axes machine and the buildup process. In addition to the influence of the process parameters, the challenging laser-wire interaction will also be explained.
M5: Laser metal deposition with powder
Laser metal deposition welding is an industrially established process for coating metallic components. Here the ability of the process is shown to build up 3D components layer by layer on 5-axes machines close to the final contour. Depending on the used system setup and the process parameters, deposition rates up to 9 kg/h as well as structure sizes in the µm range are possible.
M6: Hybrid manufacturing
Combining Additive Manufacturing (AM) and conventional production processes as subtractive machining enables enhanced production feasibilities. Presenting AM processes in general and influencing process parameters, the chances for overcoming geometrical challenges by hybrid combinations will be explained and demonstrated.
M7: Powder bed processing (SLM + EBM) The powder bed process Selective Laser Melting as well as Electron Beam Melting will be demonstrated live at the machines. The audience will be guided through the whole manufacturing workflow. This includes the digital preprocessing (CAD/CAM, Part Design), machine preparation, parameter development and post processing strategies (mechanical and thermal postprocessing).
I8: Additive solid state process for metals In solid state processes, an organic auxiliary material is used for additive shaping, whereby the component is subsequently debinded and sintered. The station will focus on three-dimensional screen printing, which extends the well-known classical screen printing by the z-axis. Properties of 3D screen printing are highly filigree components in extremely high quantities. Any metal, also ceramics and their combinations can be used.
C9: Functionalization of components
3D printing allows the manufacture of miniaturized and highly complex ceramic structural components. The 3D printing of functional layers enables the integration of additional functions (e.g. conductors, resistors, dielectric materials, sensors/ actuators, heaters). The standard thick-film technology (screen and stencil printing) offers a wide range of functional pastes which can be adapted for using digital 3D printing technologies (dispensing, micro-extrusion, ink and paste jetting, aerosol jetting). The session gives an overview about material development activities and shows application examples.
C10: Post processing – Thermoanalysis 
Since additive manufacturing of ceramic components is a powder technological shaping route, debinding and sintering steps are necessary for attaining final ceramic properties in a desired component. The participants will see thermoanalytical equipment (TG, TGA, DSC, mass spectrometry, and dilatormetry) for development of debinding and sintering routes.
C11: CerAM T3DP (Thermoplastic 3D-Printing) CerAM T3DP is a direct working AM-technology which bases on the selective deposition of molten particle-filled thermoplastic suspensions. Comparable to the drop-on-demand principle, like it is used in inkjet printers, the components were manufactured drop by drop.  Thus it is possible to deposit drops of different materials side by side and manufacture multi-material green-components. Thus property gradients can be realized within the additive produced green components. The solidification is nearly unaffected by the physical properties of the used powders. So even suspensions with metal and hardmetal powders as well as bright and dark ceramic powders can be fabricated and processed.
C12: CerAM FFF (Fused Filament Fabrication)
Fused Filament Fabrication is one of the most accepted and promising technique for additive manufacturing of polymers so far. It is a direct working AM-technology which bases on thermoplastic filaments and the selective deposition of the molten material. Various devices and materials are available. Due to the thermoplastic approach a high solid loading of ceramic particles can be compounded within the matrix to obtain fully dense parts after sintering. By using multiple print heads a multi-material manufacturing becomes feasible.
C13: CerAM Binder Jetting Binder Jetting of ceramics is mainly used for manufacturing of porous parts, like filters, catalyst supports or bone replacement structures. Furthermore, it can be used for attaining hardmetal components with a microstructure and properties comparable to conventionally made hardmetals. Binder Jetting devices and several components will be shown.
C14: CerAM VPP (Vat Photopolymerization)
CerAM VPP is an indirect working AM-technology which bases on the selective curing of photosensitive particle-filled suspensions. It was the first commercialized method for attaining dense ceramic AM-components with a very high surface quality and high precision. For this process suspensions of light curable monomers, photo initiators and ceramic powders are used. The components are built-up layer-wise hanging top down from a building platform.

*as of 25.7.2019 (subject to changes)