Additive Manufacturing

 

Laser Beam Melting (LBM)

LBM is currently the most commonly used method for the additive processing of metal powders.

The generative process of Laser Beam Melting can be used to manufacture components from metallic powders into almost any shape, even very complex ones, directly from 3D CAD data.

 

Selective Electron Beam Melting (SEBM)

Selective Electron Beam Melting (SEBM) is a powder bed-based beam-melting process for additive manufacturing of metallic components with a complex shape. The powder is selectively melted layer by layer with an electron beam.

 

Metal Binder Jetting (MBJ)

Metal Binder Jetting is a layer-by-layer manufacturing process in which a binder is deposited using printer heads – similar to inkjet printing – to create a green body in which the binder acts as an adhesive for the metal powder.

 

3D Materials Printing (3D Screen Printing)

Three-dimensional screen printing is unique in that it is the only additive process that is suitable for mass production. The 3D screen printing process involves printing layers of powder paste through a screen to produce a sinterable green body. Optional screen changes can be used to obtain the desired variety of shapes.

 

Fused Filament Fabrication (FFF)

The Fused Filament Fabrication (FFF) process is already established as a process for the generative production of plastic components. Now the process has been extended at Fraunhofer IFAM for a considerably larger range of applications by opening up the material range for metallic components. The process is characterized by a high material variety and low investment costs.

 

MoldJet® process

The MoldJet process opens up new possibilities in the design freedom of metal components and impresses with its enormous productivity. Nevertheless, it is also possible to manufacture components in quantities of one or in small to medium series.  

 

Gel Casting

With the gel casting process, Fraunhofer IFAM in Dresden has established a new technology for the production of metal components. Additive manufacturing processes are used to produce a casting mold. The actual shaping is done by pouring these moulds with a metal powder suspension at room temperature.

 

Continuous DLP

The patented (DE102012021284) process uses the technique of continuous photopolymerization according to the DLP principle. The difference to other 3D printing systems is the rotating cylinder as substrate, whose lower part dips into a polymer bath. The polymer is cured by light sources in a precisely defined distance. During the stepwise rotation of the cylinder, a three-dimensional component is built up in layers on the submerged cylinder area.

 

Lithography-based Metal Manufacturing (LMM)

LMM is a stereolithography process. It is based on a paste that is characterized by the fact that, in addition to powder and organic components, it contains a photoinitiator, which hardens under light, ultraviolet radiation especially.

Our R&D Competence#

  • Materials development
  • Consulting service for material selection and tailoring
  • Development of filaments, pastes and inks
  • Powder analysis
  • Component design and manufacture
  • Heat treatment
  • Production of prototypes and small batches
  • Support for implementation into series production
  • Economic feasibility studies

The comprehensively equipped additive manufacturing application center at Fraunhofer IFAM in Bremen comprises the complete process chain for LBM and MBJ.

At Fraunhofer IFAM in Dresden, the Innovation Center Additive Manufacturing ICAM® brings together SEBM, 3D Screen Printing, FFF, Gel Casting and soon MoldJet under one roof to provide thorough access to the various possibilities of additive manufacturing technologies.

What we offer#

  • We cover the complete value chain for the additive processes we have available at Fraunhofer IFAM – from the creation of 3D data models, through manufacturing, to final processing and inspection of the components.
  • Technological benchmarking from material to component for all processes available at Fraunhofer IFAM – in comparison to conventional manufacturing as well as comparing between the additive processes.
  • Materials development for all described processes, together with the necessary process adaptations – the material palette ranges from lightweight metals, such as aluminum and titanium, to hard metals and high-melting alloys.
  • Support for process integration – execution of technology studies and market analyses.
  • Comprehensive analysis from powder to component to ensure that the processing sequence is robust.
  • Customer-specific training courses and workshops.

Owing to its far-reaching networking and active cooperation in national and international committees, Fraunhofer IFAM is directly involved in shaping the future of technological development in the field of additive manufacturing –
for the benefit of our customers.