Industrie und Anwendungen

The main purpose of this case study was to demonstrate the potential of Laser Melting for the development of brackets for the aircraft industry. Therefore, a given bracket should be redesigned, technical and economic benefits should be analyzed.

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.

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.

The aim was to investigate, if the FDM process is suitable for the production of tool inserts (negative molds), which enables the production of finely textured metallic bipolar plates (BPP) to realize the efficient production of fuel cells.

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. Therefore, this study pursues comprehensive investigations on the mechanical properties of the titanium alloy TiAl6V4, which was processed in an optimized process chain.

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.

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.

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.