Multimaterial-AM based on Powderbed- und Extrusionsprocesses

• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Coating and Surface Technology ; Biochemistry ; Biomaterials ; Biological Process Engineering ; Synthesis and Properties of Functional Materials ; Plastics Engineering ; Lightweight Construction, Textile Technology ; Materials in Sintering Processes and Generative Manufacturing Processes ; Mechanical Properties of Metallic Materials and their Microstructural Origins ; Mechanical Process Engineering ; Metallurgical, Thermal and Thermomechanical Treatment of Materials ; Pharmacy ; Polymeric and Biogenic Materials and Derived Composites
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 533332757

Additive manufacturing (AM) offers the potential to fundamentally transform engineering, which is similar to the impact seen for AI and Big Data. Open and versatile research platforms are essential to explore scientific ideas and generate innovative solutions. The research area of Multimaterial-AM, in which the proposed equipment will be integrated into, expands the research infrastructure of HTWK to sustainably accompany and shape the transformation of engineering towards multimaterial additive manufacturing. The present application extends the existing research infrastructure with three research tools, which enable the coupling between material characterization and process development. This serves to expand expertise and create an environment for fundamental research at HTWK in the field of hybrid and generative manufacturing technologies. First, we apply for the acquisition of a powderbed fusion/IR 3D printing system, which uses inkjet printing to apply absorber materials in an image-based manner and fuses powders locally using electromagnetic energy. Commercial solutions thus far realize mechanical and optical functions. In addition to the properties of powders, the composition of the ink can be varied by active ingredients, thus creating multi-material components. This enables the integrated production of structural and, for example, electrical functionality in a single manufacturing step. The selected 3D printer processes thermoplastic powders, but can also be used as a binder jet (BJ) to functionally structure metallic, inorganic or medically relevant powder materials by using appropriate printing fluids. In addition, we suggest the acquisition of a 3D bioprinting scaffolder whose dispensing heads can be operated as fused layer modeling (FLM) and nL-droplet processes within a laminar flow box. Sterile products produced in this way can be used directly for cell colonization experiments. In-house developed print heads will be integrated in the printer, so that the system's utilization options are being expanded. By simultaneously using different print heads, hybrid structures in complex material combinations can be created. Finally, we are applying for the expansion of an existing precision rheometer towards granular media characterization, to analyze the flow of powder materials and thus use the information to optimize manufacturing processes. The combination of the devices in the research area of Multimaterial-AM allows the entire process chain to be mapped, from the characterization of the raw materials, through process-specific material and process development, to structure and property characterization. Thus, the establishment of an independent research branch and an active participation in fundamental research on a national as well as international level will be enabled.

• DFG Programme: Major Instrumentation Initiatives
• Major Instrumentation: 3D-Druck-Bioprinter inkl. Laminar Flow Box ; Powderbed-Fusion/IR-3D-Drucksystem ; Pulverscherzelle mit Feuchtigkeits- und Temperaturregelung
• Instrumentation Group: 2110 Formen-, Modellherstellung und gießereitechnische Maschinen
• Applicant Institution: Hochschule für Technik, Wirtschaft und Kultur Leipzig
• Leader: Professor Dr.-Ing. Ingo Reinhold
• Co-Investigators: Professor Dr.-Ing. Faouzi Derbel; Dr.-Ing. Tobias Flath; Professor Dr.-Ing. Paul Rosemann; Professor Dr.-Ing. Fritz Peter Schulze