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Project name:

Post-processing of complex shaped, additive manufactured parts with high demands on accuracy and surface integrity

Status: Idea
Creation date: 23-02-2023

Project objectives:

Short summary A German university develops process chains, technologies and tools for micro and precision manufacturing. In addition to the production of components with dimensions on a µm-scale, a main topic is the specific functionalization of surfaces in terms of surface quality and chemical-physical properties. Contacts are sought with industry and research institutes from the field of additive manufacturing (AM). In particular, R&D agreements with focus on post-processing of AM parts are of interest.

Full description A major advantage of additive manufacturing is the significantly greater design freedom in the development of new products, components or parts. Also, a growing need for components with increasing complexity and high functionality for different industrial applications exists. At this time the applicability of additive manufacturing processes is still partially limited. Especially the precision, the reliability and the achievable surface qualities often do not meet the specific requirements. Post-processing procedures are therefore often necessary to achieve the desired accuracy and surface roughness. Also support structures and partially molten particles must be removed by post-processing. The German research group is focused on the further development of technologies for the post-processing of additive manufactured parts and on the design of appropriate processing strategies. Various cutting and ablating technologies are available for processing. Tools for process design in the form of simulation software are also available. Furthermore, the research group gained experiences in localized machining, in processing hard to machine materials and in the controlled influencing of the surface layer properties. The group is looking for R&D partners from industry or research institutes with special demands on the surface integrity of additive manufactured parts. The type of cooperation takes place, for example, within the framework of a research cooperation in order to submit joint project ideas in the mentioned field.

Advantages and innovations
  • Process und technology development in dependence on the requirements, e.g.:
  • - Complexity of the geometry
  • Surface integrity
  • Accuracy
  • Material
  • Resource efficiency and environmental friendliness
  • Depending on the requirements, use of manufacturing processes without thermal and mechanical influences
  • Application of plasma polishing processes for high surface qualities
  • Technical solutions available for localized post-processing
  • Strategies for post-processing of complex shaped components present
  • Design and modification of tools for cutting and ablating processes
  • Process development for difficult to machine and heterogeneous materials (e.g. metal matrix composites)
  • Modelling of manufacturing processes to identify relevant process parameters and for tool design
  • Multiphysical simulations for the design of functional surfaces or components

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