Laser beam melting

Manufacturing beyond current process limits #

We research and develop application of the additive manufacturing process laser beam melting for tool-free manufacturing of metal components with geometric peculiarities which cannot be manufactured by conventional production technologies. Novel tools and molds of steel are developed with integrated near-net-shape cooling and tempering channels for primary shaping and forming technology. Moreover, medical titanium implants with customized geometries or internal functional structures for improved healing and higher patient comfort.

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Tool making – active components for forming tools

  • Near-net-shape tempering in press hardening
  • Process optimization in die casting

Component manufacturing – manufacturing beyond technological boundaries

  • Heat exchanger with optimized structure
  • Longboard carrier with optimized topology

Medical engineering and implant manufacturing

  • Implant with internal channels and cavities

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  • Tool-free manufacturing– directly based on 3D CAD data
  • No costly process engineering, no NC programming
  • Direct digital manufacturing and rapid prototyping
  • Almost arbitrarily complex geometries (undercuts, internal geometries, delicate cavity structures/ framework structures)
  • Bionic structures and components with 100% optimized topology
  • Geometries that cannot be generated by cutting/forming/casting
  • Material variety (hot-work steel, stainless steel, nickel-base alloy, cobalt-chromium, aluminum, titanium)

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Tool making – active components for primary shaping tools and forming tools

  • Development and manufacturing of innovative tool systems with added value such as near-net-shape tempering
  • Implementation of laser beam-melted tool inserts into the complete tool
  • Supervision of run-in in production and evaluation of cycle time, tool life, quality and dimensional stability of the components

Component manufacturing – manufacturing beyond technological boundaries Rapid prototyping using metal production material

  • Direct manufacturing of components for series application
  • Development of components with lattice structure or bionic structure, for example for the aerospace industry
  • Development of components and assembly groups for thermal regulation, for example for power electronics (electric mobility)
  • Development of complex components for process engineering

Medical engineering and implant manufacturing

  • Design, construction and manufacturing of patient-specific implants
  • Feasibility studies for novel medical applications
  • Integration of innovative functions into implants

Process development

  • Qualification of new materials following customer requests
  • Process simulation
  • Quality assurance

Links to related research domains

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Machine technology

  • Laser beam melting plant Concept Laser M2 Cusing (400-W fiber laser, machining range (x, y, z):     250 x 250 x 280 mm³)
  • Laser beam melting plant Realizer SLM 100 (100-W fiber laser, machining range (Ø, z): 125 x 80 mm³)
  • 2 micro beam plants PEENMATIC 620 S
  • Micro vibrator P30
  • Hardening system

Software

  • Design (CREO, CATIA, SOLIDWORKS)
  • Simulation (ANSYS, LS-DYNA, Simufact.welding)
  • Specific software (Magics, 3-matic, Autofab)

Inspection technology

  • GOM ATOS III Triple Scan 3D scanner
  • phoenix v|tome|x s µCT scanner
  • Materials laboratory (REM, dilatometer etc.)