Process & System Development

Through the development and integration of customized process strategies, innovative hardware, and novel monitoring and control systems, we assist you in the industrialization of your AM manufacturing process. Optimal manufacturing parameters enhance material properties and increase the sustainability, productivity, and economic viability of your processes.

Fraunhofer IAPT supports you in the industrial utilization of additive manufacturing by developing resource-efficient AM processes and systems, from feasibility studies to the qualification of complete process chains

Our team‘s core competencies lie in selective laser melting (Laser Powder Bed Fusion, L-PBF), directed energy deposition (DED), sintering-based processes (Sinter AM), and polymer-based AM methods (Polymer AM).

The Process Qualification team at Fraunhofer IAPT supports your industrial use of Additive Manufacturing by developing resource-efficient, stable, and productive AM processes and systems, from feasibility studies to the qualification of complete process chains. Our team‘s main focus is in developing industry-driven AM processes Laser Powder Bed Fusion (L-PBF), Directed Energy Deposition (DED), sinter-based metal AM processes, as well as polymer-based AM methods.

Beyond systems for better component quality in the manufacturing process, we characterize and qualify metallic powders and additively manufactured components. We have a fully equipped materials laboratory for sample preparation and measurement technology to characterize microstructure, mechanical, and physical properties. This allows us to meet your requirements using the latest measurement and testing methods.

Qualifying Your Materials and Processes

Optimal manufacturing parameters improve material properties and enhance the sustainability, productivity, and economic efficiency of your processes. Based on state-of-the-art equipment, we develop process parameters and qualify your materials and additively manufactured components. For sample preparation and measurement technology to characterize microstructure, mechanical, and physical properties, we have access to a fully equipped materials lab.

Increasing Productivity and Process Stability

Enhancing stability and productivity as well as ensuring the quality of industrial AM processes is at the core of our process development activities. We integrate and qualify novel programmable high-performance lasers, including beam shaping systems. We develop solutions for the safe and productive manufacturing of complex components, create adaptive manufacturing strategies, and offer customized in-process monitoring solutions for high-productive manufacturing.

In-Process Monitoring and Control

For all our AM processes, we develop and test systems for in-situ monitoring of the manufacturing process. We implement and combine various systems such as optical cameras, thermography, optical coherence tomography (OCT), or eddy current sensors. We analyze the collected data using computer vision and machine learning with the goal of achieving complete in-situ process control.