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Innovation

Durch die Forschung des DMRC konnten einige Innovationen entwickelt werden. Diese Innovationen treten in verschiedenen Forschungsfeldern auf und werden hier näher dargestellt.

For applications in electrical machines, AM provides exciting new possibilities. The process-specific freedom of design enables themeconomical production of geometrically complex components, since the component complexity has only a minor influence on the production costs.

Mehr Informationen zu einem topologieoptimierten und additiv hergestellten Bracket für die Luftfahrtindustrie.

In order to save resources and adapt parts better to their requirements, companies are focusing on part optimization for lightweight design. Unfortunately, the existing software for topology optimization is characterized by several shortcomings: Modeling is a lengthy, labor-intensive process,the computing time is long and extensive expertise and manual reworking is required.

Additive manufacturing (AM) of metal components attracts substantial attention. By employing AM, highly complex parts can be generated with additional functionalities such as contour near cooling, sensor systems, or permeable structures. With regard to selective laser melting filigree parts can be generated in a near net shape fashion. However, alloys processible via SLM are limited. Improved SLM manufacturing conditions can be achieved either by material adjustments consistent powder heating up to 800 °C.

Vorteile der additiven Fertigung am Beispiel der Funktionsintegration von gedämpften Strukturen. Anwendungsbeispiel Ankerscheibe in einer Federkraftbremse.

Markings can be understood as a kind of individualization of parts. As individualization does not increase production costs when using AM the only effort results from the integration of markings in the digital product data.

In this study, together with ESA, the suitability of AM for components on satellites was investigated. The result based on topology optimization is a futuristic-looking component that scores technically and economically in many points.

Zur Fertigung von sehr fein strukturierten Bipolarplatten wurde ein geeingentes Fertigungsverfahren gesucht. Das FDM-Verfahren bietet hier aufgrund der Prozesscharakteristik sehr viele Vorteile, um passende Werkzeuge für die Umformung herzustellen.

The focus of the scientific work of the Chair of Design and Drive Technology (KAt) are electromechanical drive technology and design aspects in additive manufacturing processes. In the research project “KAtAMaran” (“Design and drive technology in an AM-optimized modular drive”), a modular multi-motor drive system (short: MMDS) is being developed as a research platform that exhibits the design freedom of additive manufacturing and the advantages of function integration.

Additive manufacturing processes are playing an increasingly important role in the field of medical technology. They make it possible to meet the demand and need for patient-specific products. The high design freedom of additive manufacturing processes in combination with CAE methods is used to provide approaches to solve the existing stiffness problem in hip endoprosthetics. Using stress adapted geometries and the finite element method, stiffness adapted variants of a short shaft hip endoprosthesis are developed in an iterative process.

In times of Covid-19 the DMRC and partners became active helping hospitals and social institutions with additive manufactured personal protective equipment. Together with medical device manufacturer Condor MedTec and several hospitals in and close to Paderborn, the project team defined the requirements for the faceshields.

The reduction of process times in additive manufacturing is a major focus of research. The aim of the investigation was to reduce the time, required for a process route, of the additive manufacturing process for the Ti6Al4V titanium alloy with subsequent HIP process. Procedure Therefore, this study pursues comprehensive investigations on the mechanical properties of the titanium alloy TiAl6V4, which was processed in an optimized process chain.

Machbarkeitsstudie zum Einsatz von additiven Fertigungsverfahren zur Fertigung von Bauteilen für die Elektrotechnik. Besonderes Beispielbauteil ist hier ein Permanent Magnet Synchronous Motor (PMSM).

Temperature effects in the polymer laser sintering process are an important aspect regarding the process reproducibility and part quality. Depending on the job layout and position within the part cake, individual temperature histories occur during the process.

The processing of metal powder filled polymer filaments in Fused Deposition Modeling (FDM) presents a comparatively new technology for the production of metal components. This technology enables powder-free handling of the base material and processing on low-cost FDM equipment.

Technische und wirtschaftliche Machbarkeitsstudie zum Einsatz des SLM-Verfahrens für eine hydraulische Spannvorrichtung. Mittels Topologieoptimierung konnte eine hohe Gewichtsersparnis erreicht werden.

The laser-sintering process has, beside all the advantages like a high productivity and a great design freedom, significant disadvantages with the low material variety and material ageing. A major proportion of all LS components are still made of PA12 and PA11. High performance materials e.g. PA6, PPS, PEKK, etc. are appearing increasingly on the market but they cannot be processed on standard LS systems due to the higher processing temperature. High temperature systems, on the other hand, are very cost-intensive.

The collaborative project OptiAMix, funded by the BMBF, was initiated for multi-target optimized and continuously automated component development for additive manufacturing processes in the product development process. To accelerate the spread of additive manufacturing in the industrial environment, the process capability, the economic efficiency and the reliability of the processes has to be improved.

Experience from conventional manufacturing shows a good performance of the high-strength aluminum alloy EN AW 7075 which leads to frequent use in automotive and aerospace sector. Scientific investigations on the processability of this alloy in the SLM process shows that prepared samples have anisotropic behavior due to process-induced hot cracks. Furthermore, it was not possible to determine solid results regarding the fracture mechanical characterization.

Machine and part qualification are always based on the information gathered. For a proper qualification and for confidence gaining in the LS technology the process itself should be observed and monitored as precisely as possible. Within this DMRC project a high-resolution images-based powder spread monitoring system for the laser sintering process has been developed. For each layer an image is captured and fed to a Region Based Convolutional Neural Network (Mask R-CNN) feature detection software, where it is analysed for powder spread flaws. The software is capable to detect point, line and…

Selective laser melting (SLM) is a powder bed-based additive manufacturing process for the production of metallic, highly complex components. With regard to tool manufacturing for forming production (e.g. extrusion, deep drawing), an almost unrestricted freedom of design enables the integration of cooling channels close to the contour in order to reduce hot spots, so that the component distortion of the semi-finished product is minimized, the service life of the tool is extended and the process time is shortened. As a result of the near-contour filigree production, machining can also often…

A design adjustment of the inner structure minimizes the floating overhangs in the range of the flow channels. Due to this adjustment, the use of any kind of support material can be avoided. In this way it can be ensured that no residues of water soluble or non-biocompatible material remain in the system.

A component is created in the Fused Deposition Modeling (FDM) process by depositing a polymer strand layer by layer. Due to thermal fusion, the deposited material bonds with the layer below. This leads to the characteristic welded seams of the FDM process. Therefore, an essential part of the qualification of new materials for the FDM process is the evaluation of the processing suitability by means of the weld seam quality. The aim of the research in cooperation with DMRC industrial consortium is to drive forward the material qualification of high-performance polymers.

The surfaces of additive components are not as smooth as for conventional machined parts due to the manufacturing process. Therefore, AM manufactured components require a surface post treatment.

The layered structure of Additive Manufacturing processes results in a stair-stepping effect of the surface topographies. In general, the impact of this effect strongly depends on the build angle of a surface whereas the overall surface roughness is caused by the resolution of the specifi c AM process. The aim of this work is the prediction of surface quality in dependence of the part building  orientation.

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