In collaboration with the Lightweight Construction and Hybrid Construction Methods Working Group, research is being conducted into algorithms for model generation and optimization and simulation tools to enable sound component design. Concept development forms the basis for establishing new approaches in product development and generating innovative solutions.
Furthermore, the characterization of additively manufactured structures and components is being advanced in order to identify essential characteristics and properties at an early stage, thereby ensuring that requirements are met and enabling comparison with conventional construction methods. One goal of characterization is to clarify and quantify geometric and process-specific factors that influence the resulting mechanical and technological properties or properties such as electrical conductivity.
The component design is based on many years of experience in the field of component design in the context of additive manufacturing and is supported by the development of methods and tools. Through the production and testing of components using additive manufacturing, the design principles and rules are continuously updated and the understanding of the process is expanded based on the quantification of the influences between geometry definition, process parameter selection, and production on the resulting component properties. One focus in component design is on functional integration through additively manufactured multi-material construction methods.
Another field of research is additive manufacturing of acoustically effective structures for reducing structure-borne or airborne noise by specifically using the new design freedoms offered by additive manufacturing technologies to fulfill acoustic functions. Concepts are being developed and component designs are being created, taking specific manufacturing restrictions into account. In addition to the realization of integrated damping structures using multi-material construction, porous absorbers are also being investigated.
Materials with shape memory properties can be used to create adaptive structures and actuators, which can be reset to a previously programmed shape, for example, through thermal activation. In addition to investigating design options and the limits of potential areas of application, research is also being conducted into the local integration of activation mechanisms in multi-material construction methods, for example, through additively manufactured heat-generating structures.
In the field of additive manufacturing of electrically conductive structures, the integration of heat-generating structures and piezoresistive sensors is currently being investigated. In addition to analyzing the influence of the process and geometry on electrical conductivity with a view to specifically adjusting the electrical resistance, research is being conducted into the robust processing of electrically conductive polymers with different fillers and contacting concepts. In addition, potential fields of application (including air conditioning, electrical conductor tracks, monitoring functions) for additively manufactured multi-material designs with electrical properties are being investigated.
The development and manufacture of multi-material construction methods requires consideration of the material composite. Therefore, methods for characterizing and designing the material composite are being researched at the IK. To design the material composite, measures to increase composite adhesion, such as form fits or pretreatment measures, are being investigated. This makes it possible to integrate material-specific functions with regard to the combination of incompatible or poorly compatible materials.
Due to the limited installation space available in additive manufacturing facilities, suitable joining methods are being investigated. Adhesive bonding has been identified as a suitable joining technology for this purpose. The investigations include the analysis of process influences of additive manufacturing technologies (plastic and metal) on the suitability for bonding in comparison to conventional processes (including injection molding and die casting) and the derivation of rules for bonding additively manufactured components. In addition, methods are being developed to enable the bonding of plastics that are difficult to bond without pre-treatment measures.
In order to expand the areas of application for additive manufacturing technologies, modifications are also being made to existing systems and new system technology is being developed within research projects.
For example, the AGENT-elF and 3D4Space research projects are developing additive manufacturing systems for high-melting mineral materials such as glass and ceramics, with the aim of expanding the potential fields of application for additive manufacturing. In both cases, the basis is the material extrusion process, for which systems with extrusion temperatures of over 1000°C are being developed. In addition to the thermal stress on the system caused by the processing temperature, particular attention must be paid to thermal stresses in the component.
The OpenBioPrint research project (link) is developing a production facility that enables the processing of UV-curing materials. The aim of the project was to process silicone using digital light processing. In addition, the technology was to be made accessible to citizen science. The modular design of the system allows for individual system configuration and adaptation to specific requirements. This lays the foundation for an open innovation process involving citizen science.