Initial Situation:
A range of additive manufacturing techniques are available for manufacturing complex structures in a cost-saving way. Customized structures with integrated functions can be manufactured in a weight-saving and custom-fit manner. The analysis of product requirements and the definition of an adequate additive manufacturing technique are complex and involve multi-objective optimisation, for which no guidance is available. It cannot be said for certain which mechanical properties layered structures produced by additive manufacturing have compared with components made from solid material. However, the resulting component quality plays a significant role and should be validated when selecting a manufacturing technique in order to build lasting, widespread trust in additive manufacturing. Unfortunately, achievable quality characteristics are not always validated.
GOALS:
The goal of the project is the scientific qualification of additively manufactured components with integrated functions. This should be performed specifically for the various additive manufacturing techniques in combination with the optimisation of these processes in terms of the various component requirements. The aim is to determine the requirements placed on component quality systematically and to examine which component quality can be achieved through additive manufacturing. A sensory process and quality monitoring system with adequate data collection and processing is to be developed and research is to be conducted into quality assurance performed on the basis of the data collected by the sensors. Another goal is to engineer a suitable IT services platform with selection tools which draws on a knowledge-based and data-based methodology. An additive manufacturing user, developer and research map is to be developed to close gaps in the current R&D and company network.
Process:
The project is split into three phases. The preliminary phase entails an analysis of the current status, including benchmark tests with the project partners. During this phase, technical feasibility is to be checked and the relevant additive manufacturing techniques selected. The first phase largely focuses on the integration of functions and the further development of the manufacturing methods. This phase also involves a scientific qualification of additively manufactured components, specifically for the various manufacturing processes. In addition, a guideline for the optimisation of these processes is to be compiled. Shortcomings in terms of technology, quality and costs and necessary quality assurance tools are to be identified during this phase, which also involves data acquisition and quality monitoring. Project knowledge management for additively manufactured components becomes relevant in the last phase of the project. A network or IT service platform for the selection of appropriate manufacturing techniques, for quality validation and for redesign processes to integrate functions into a component is to be designed during this phase.
