@article{62160, abstract = {{Laser powder bed fusion is a cornerstone technology for additive manufacturing (AM) of metals and polymers, yet challenges in achieving consistent reproducibility and process optimization persist. Addressing these requires a systematic understanding of the interactions between feedstock, process parameters, and final part characteristics throughout the entire production chain. This study presents results from a comprehensive interlaboratory investigation conducted by 32 research institutions, evaluating six feedstock, including nanoparticle‐modified aluminum alloy and polyamide powders, under standardized protocols. Data analysis encompasses 69 powder properties, 15 process parameters per print, and 78 part features, culminating in a dataset of over 1.2 million correlations. Advanced statistical methods and machine learning are employed to identify critical variability drivers, such as the impact of nanoparticle modifications on powder flowability and thermal conductivity, as well as the influence of process parameters on reproducibility. Newly introduced dimensionless figures of merit provide universal metrics to describe and predict thermal and mechanical interactions, simplifying process optimization and material characterization. The findings, supported by an open‐access dataset adhering to findable, accessible, interoperable, and reusable principles, advance understanding of material–process–structure–property relationships. They establish a benchmark for future research and lay the foundation for improving the reliability, quality, and sustainability of AM processes.}}, author = {{Kuşoğlu, Ihsan Murat and Garg, Sunidhi and Abel, Arvid and Balachandran, Prasanna V. and Barcikowski, Stephan and Becker, Louis and Bernsmann, Jan-Simeon and Boseila, Jonas and Broeckmann, Christoph and Coskun, Mert and Dreyer, Malte and East, Mark and Easton, Mark and Ellendt, Nils and Gann, Stan and Gökce, Bilal and Goßling, Mareen and Greiner, Joachim and Gruber, Piotr and Grünewald, Moritz and Gurung, Kopila and Hantke, Nick and Hengsbach, Florian and Holländer, Hannes and Van Hooreweder, Brecht and Hoyer, Kay-Peter and Huang, Yajiang and Huber, Florian and Kessler, Olaf and Kısasöz, Burçin Özbay and Kleszczynski, Stefan and Koc, Ebubekir and Kurzynowski, Tomasz and Kwade, Arno and Leupold, Simon and Liu, Dongmei and Lomo, Felix and Lüddecke, Arne and Luinstra, Gerrit A. and Mauchline, David A. and Meyer, Fabian and Meyer, Lars and Middendorf, Peter and Nolte, Stefan and Olejarczyk, Michał and Overmeyer, Ludger and Pich, Andrij and Platt, Sebastian and Radtke, Felix and Ramm, Roland and Rittinghaus, Silja-Katharina and Rothfelder, Richard and Rudloff, Johannes and Schaper, Mirko and Scheck, Marie Luise and Schleifenbaum, Johannes Henrich and Schmidt, Michael and Sehrt, Jan T. and Shabanga, Yvonne P. and Sommereyns, Alexander and Steuer, Rabea and Tisha, Layla Shams and Toenjes, Anastasiya and Tuck, Christopher and Vaghar, Adrian and Vrancken, Bey and Wang, Zhengze and Weber, Sebastian and Wegner, Jan and Xu, Bai-Xiang and Yang, Yangyiwei and Zhang, Duyao and Zhuravlev, Evgeny and Ziefuss, Anna R.}}, issn = {{1438-1656}}, journal = {{Advanced Engineering Materials}}, number = {{14}}, publisher = {{Wiley}}, title = {{{Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers}}}, doi = {{10.1002/adem.202402930}}, volume = {{27}}, year = {{2025}}, } @techreport{63209, abstract = {{Die DFG-Projekte AddFeRo-PM (406108415) und AddFeRo-SR (465089065) untersuchten die Potenziale des LB-PBF/M-Verfahrens zur Herstellung von Rotoren für unterschiedliche elektrische Maschinen. Im interdisziplinären Ansatz wurden Materialentwicklung und mechanische sowie elektromagnetische Optimierung verbunden. Im Projekt „AddFeRo-PM“ wurde der Rotor einer permanentmagneterregten Synchron- maschine (PMSM) untersucht. FeSi erwies sich als geeignete Legierung, konnte aber wegen Spannungsrissen nur bis zu 3 % Siliziumanteil (kurz: FeSi3) verarbeitet werden. Mechanische und elektromagnetische Untersuchungen ermöglichten eine 3D-Optimierung der Rotorgeometrie und -struktur. Der Demonstrator wurde additiv gefertigt und zeigt Leicht-baupotenziale sowie reduzierte Drehmomentwelligkeit. Im Folgeprojekt „AddFeRo-SR“ kam eine Hochtemperatur-Bauraumheizung (HTBH) zum Einsatz, die FeSi mit 6,5 % Siliziumanteil verarbeitbar machte, welches bessere elektro- magnetische Eigenschaften bietet. Sie wurde bei einer Synchron-Reluktanzmaschine (SynRM) getestet. Eine hybride Rotorfertigung erwies sich jedoch aufgrund von HTBH-Einschränkungen als ungeeignet, weshalb eine einteilige Fertigung mit FeSi3 umgesetzt wurde. Experimente bestätigten vergleichbare Betriebsergebnisse zur konventionellen Fertigung bei reduzierter Rotormasse. Zusätzlich wurde eine Methodik entwickelt, um additive Verfahren als Ergänzung zur konventionellen Fertigung zu integrieren. Beide Projekte zeigen das Potenzial additiver Fertigung für Leichtbau und Wirkungsgradsteigerung im Elektromaschinenbau und bieten wertvolle Grundlagen für industrielle Anwendungen.}}, author = {{Haase, Michael and Behrendt, Marius and Hengsbach, Florian and Kunnathully Sathees Kumar, Vinay and Magerkohl, Sebastian and Magyar, Balázs and Ponick, Bernd and Schaper, Mirko and Zimmer, Detmar}}, keywords = {{Additive Fertigung, Elektromotor, Leichtbau, Synchronmotor, DFG}}, publisher = {{Technische Informationsbibliothek}}, title = {{{Additive Fertigung im Elektromaschinenbau: Erforschung von Potentialen der additiven Fertigung in Rotoren permanentmagneterregter Synchronmaschinen}}}, doi = {{10.34657/26753}}, year = {{2025}}, } @article{23898, author = {{Andreiev, Anatolii and Hoyer, Kay-Peter and Dula, Dimitri and Hengsbach, Florian and Haase, Michael and Gierse, Jan and Zimmer, Detmar and Tröster, Thomas and Schaper, Mirko}}, issn = {{0924-0136}}, journal = {{Journal of Materials Processing Technology}}, title = {{{Soft-magnetic behavior of laser beam melted FeSi3 alloy with graded cross-section}}}, doi = {{10.1016/j.jmatprotec.2021.117183}}, year = {{2021}}, } @inproceedings{16048, author = {{Ahlers, Dominik and Tröster, Thomas and Hermann, S. and Koppa, P. and Gloetter, P. and Schaper, Mirko and Peters, M. and Burns, M. and Hengsbach, Florian and Altmann, A.}}, booktitle = {{Contributed Papers from MS&T17}}, isbn = {{9780873397667}}, title = {{{Selective Laser Melting of Ti6Al4V with High Build Rates and Following Hot Isostatic Pressing}}}, doi = {{10.7449/2018mst/2018/mst_2018_117_124}}, year = {{2018}}, } @article{41525, author = {{Hengsbach, Florian and Koppa, Peter and Holzweissig, Martin Joachim and Aydinöz, Mehmet Esat and Taube, Alexander and Hoyer, Kay-Peter and Starykov, Oleksiy and Tonn, Babette and Niendorf, Thomas and Tröster, Thomas and Schaper, Mirko}}, issn = {{2363-9512}}, journal = {{Progress in Additive Manufacturing}}, keywords = {{Industrial and Manufacturing Engineering}}, number = {{4}}, pages = {{221--231}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Inline additively manufactured functionally graded multi-materials: microstructural and mechanical characterization of 316L parts with H13 layers}}}, doi = {{10.1007/s40964-018-0044-4}}, volume = {{3}}, year = {{2018}}, } @article{24104, author = {{Hengsbach, Florian and Koppa, Peter and Holzweissig, Martin Joachim and Aydinöz, Mehmet Esat and Taube, Alexander and Hoyer, Kay-Peter and Starykov, Oleksiy and Tonn, Babette and Niendorf, Thomas and Tröster, Thomas and Schaper, Mirko}}, issn = {{2363-9512}}, journal = {{Progress in Additive Manufacturing}}, pages = {{221--231}}, title = {{{Inline additively manufactured functionally graded multi-materials: microstructural and mechanical characterization of 316L parts with H13 layers}}}, doi = {{10.1007/s40964-018-0044-4}}, year = {{2018}}, } @article{15957, author = {{Hengsbach, Florian and Koppa, Peter and Holzweissig, Martin Joachim and Aydinöz, Mehmet Esat and Taube, Alexander and Hoyer, Kay-Peter and Starykov, Oleksiy and Tonn, Babette and Niendorf, Thomas and Tröster, Thomas and Schaper, Mirko}}, issn = {{2363-9512}}, journal = {{Progress in Additive Manufacturing}}, pages = {{221--231}}, title = {{{Inline additively manufactured functionally graded multi-materials: microstructural and mechanical characterization of 316L parts with H13 layers}}}, doi = {{10.1007/s40964-018-0044-4}}, year = {{2018}}, } @article{41530, author = {{Hengsbach, Florian and Koppa, Peter and Duschik, Kristina and Holzweissig, Martin Joachim and Burns, Madison and Nellesen, Jens and Tillmann, Wolfgang and Tröster, Thomas and Hoyer, Kay-Peter and Schaper, Mirko}}, issn = {{0264-1275}}, journal = {{Materials & Design}}, keywords = {{Mechanical Engineering, Mechanics of Materials, General Materials Science}}, pages = {{136--142}}, publisher = {{Elsevier BV}}, title = {{{Duplex stainless steel fabricated by selective laser melting - Microstructural and mechanical properties}}}, doi = {{10.1016/j.matdes.2017.07.046}}, volume = {{133}}, year = {{2017}}, } @inproceedings{16066, author = {{Ahlers, Dominik and Koppa, Peter and Hengsbach, Florian and Gloetter, P. and Altmann, A. and Schaper, Mirko and Tröster, Thomas}}, booktitle = {{Proceedings of the 28th Annual InternationalSolid Freeform Fabrication Symposium – An Additive Manufacturing Conference}}, location = {{Austin, Texas, USA}}, title = {{{Increasing process speed in the laser melting process of Ti6Al4V and the reduction of pores during hot isostatic pressing}}}, year = {{2017}}, } @article{24108, author = {{Hengsbach, Florian and Koppa, Peter and Duschik, Kristina and Holzweissig, Martin Joachim and Burns, Madison and Nellesen, Jens and Tillmann, Wolfgang and Tröster, Thomas and Hoyer, Kay-Peter and Schaper, Mirko}}, issn = {{0264-1275}}, journal = {{Materials & Design}}, pages = {{136--142}}, title = {{{Duplex stainless steel fabricated by selective laser melting - Microstructural and mechanical properties}}}, doi = {{10.1016/j.matdes.2017.07.046}}, year = {{2017}}, }