Powder Bed Processes and Printing

Additively manufactured coating head with filigree structures made of pure copper.
© Fraunhofer IWS
Additively manufactured coating head with filigree structures made of pure copper.

The work focuses on the development of powder bed-based processes for metallic 3D print as well as printing processes for the fabrication of complex electronic structures. The range of processes includes laser-based processes such as laser powder bed fusion (PBF-LB) and binder jetting (BJ), as well as electron beam melting (PBF-EB), (metal) fused filament fabrication (FFF), dispenser printing and aerosol jet printing. For the selective heat treatment of additively manufactured parts, various furnaces with controlled atmospheres are employed.

 

Our Range of Services Includes:

  • Process development: Powder bed-based additive manufacturing and printing of electronic structures
  • Thermal post-treatment with different lamps (IR and flash)
  • Heat treatment in controlled atmosphere (e. g. pure hydrogen)
  • Paste and ink development
  • Development of system components

Research Topics

Processes

  • Powder bed processing
  • 3D printing
  • Pre and post treatment

Applications

  • Aerospace technology
  • Medical engineering
 

Equipment

  • Heat treatment
  • Paste and ink production
  • Analytics

Projects

ASPIRER

AeroSPIke Rocket Engine Realisation, Timeframe: 04/2020–03/2025 (European Space Agency ESA)

BioGrip

Intelligent gripping tool with self-adaptive properties, Timeframe: 07/2021–06/2022 (BMBF: FKZ 02P20E110)

BLITZER

Bringing a Binder Jetter Solution for Innovative Technology and Material Developments to Application Maturity, Timeframe: 11/2024–04/2026 (SMWA, FKZ: 100737948)

EDWIM

Energy Dense Wind Powertrains Through Sustainable Innovative Manufacturing, Timeframe: 05/2026–04/2029 (EU)

FAST/AGIL

Rapid prototype development for future-proof aviation, Timeframe: 09/2022–08/2026 (BMWK, FKZ: 20L2105B1)

KryoHeater

Printed heater for space structures

SAB Project

Simsalabim

Simulation of Sinter-based Additive Manufacturing Processes for Metallic High-temperature Materials Aimed at Establishing a Saxon Network, Timeframe: 05/2024–09/2027 (SAB)

SMILE

Surface coating and microstructuring for compound functionalised biomaterials in dentistry, Timeframe: 07/2022–06/2025 (M-ERA.NET Call 2021, FKZ: 100 638 788)

SpreeTec neXt

New Manufacturing Technologies for Components and Systems of Decentralized Power Engineering, Timeframe: 10/2022–12/2029 (BMBF, FKZ: 02P21Z001)

News and Media

 

News / 6.2.2025

Innovative Hot Gas Test: A Milestone for Aerospike Engines

First Successful Test of a Generatively Manufactured Aerospike Engine Using Hydrogen Peroxide-Kerosene Propellant

 

Press Release / 3.12.2024

Cost Effective Production of High-temperature Components Using 3D Printing

Project “Simsalabim”

 

Press Release / 27.10.2023

Fraunhofer IWS Installs Europe’s Unique Industrial 3D Printer

“SpreeTec next”: Powder Bed-Based Additive Laser Manufacturing System