3D Printing

TH Mittelhessen wants to improve metal 3D printing

TH Mittelhessen wants to improve metal 3D printing

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New metal laser beam process could further revolutionize metal 3D printing

One of the most impressive and at the same time most complex 3D printing processes is undoubtedly the metal 3D printing, which is why so far only a few professional providers are active in this field – apart from universities and other research institutions. In addition to the demanding handling, it is above all the high costs of metal 3D printers that prevent many potential 3D printing users from having metal 3D printed or even printing with metal themselves.

A research project by the TH Mittelhessen (press release) could change that now. In a research project funded by the state of Hesse with 300,000 euros, a team of experts from the TH in Gießen is currently developing a new one Metal laser beam melting processwhich should decisively optimize metal 3D printing.

The sticking point in metal 3D printing: there are no suitable production parameters

The reason for this is not least the fact that metal 3D printing has so far been used in the aviation industry as well as in dental and medical technology, but for its use in engineering and automotive industries However, there is a lack of essential knowledge about suitable production parameters. Questions to be clarified in particular are the optimum layer thickness, the positioning of the 3D printed object in the construction space and the question of the optimum temperature and energy density of the laser. While there have been characteristic values ​​for the construction and design of a component for decades for the common manufacturing processes (such as rolled steel or die-cast aluminum in particular), these have not been available for 3D printing with metal so far. Exactly this gap should finally be closed thanks to the Giessen research project.

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Over 400 individual tests planned

More than 400 individual tests are therefore planned, in which components from a Steel- and one aluminum alloy to be investigated experimentally. In order to limit the number of costly tests, the researchers want to use the computer to simulate the behavior of the components produced using the new metal 3D printing process. The Friedberg professor Doctor Udo Jung, alongside Doctor Heinrich Friederich from the Competence Center Traffic – Mobility – Automotive one of the leaders of the research project, summarizes its objective as follows: “We will summarize the results in a specific set of instructions, according to which these components with reliable and reproducible properties can be produced. It serves the designers as a means for the safe design of components with high process reliability and quality”.

Like every variant of rapid prototyping, metal laser beam melting is also based on the construction of a 3D printed object using the layer process. The laser beam of the metal 3D printer merges, controlled by a CAD data setat temperatures of a few 100 degrees Celsius very thin layers of powder together, with the processing taking place layer by layer in a vertical direction.

TH Mittelhessen wants to improve metal 3D printingTH Mittelhessen wants to improve metal 3D printingAt 3D Activation you will find numerous possibilities to implement your 3D printing projects out of metal. Our selection of 3D printable metals ranges from aluminum to brass and nickel to silver. Simply visit our website.

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