@article{63072,
  abstract     = {{<jats:p>Titanium alloys are widely employed for biomedical implants due to their high strength, biocompatibility, and corrosion resistance, yet their lack of intrinsic antibacterial activity remains a major limitation. Incorporating copper, an antibacterial and β-stabilising element, offers a promising strategy to enhance implant performance. This study investigates Ti-6Al-7Nb modified with 1–9 wt.% Cu via in situ alloying during metal-based laser powder bed fusion (PBF-LB/M), with the aim of assessing processability, microstructural evolution, and mechanical properties. Highly dense samples (&gt;99.9%) were produced across all Cu levels, though chemical homogeneity strongly depended on processing parameters. Increasing Cu content promoted β-phase stabilisation, Ti2Cu precipitation, and pronounced grain refinement. Hardness and yield strength increased nearly linearly with Cu addition, while ductility decreased sharply at ≥5 wt.% Cu due to intermetallic formation, hot cracking, and brittle fracture. These results illustrate both the opportunities and constraints of rapid alloy screening via PBF-LB/M. Overall, moderate Cu additions of 1–3 wt.% provide the most favourable balance between mechanical performance, manufacturability, and potential antibacterial functionality. These findings provide a clear guideline for the design of Cu-functionalised titanium implants and demonstrate the efficiency of in situ alloy screening for accelerated materials development.</jats:p>}},
  author       = {{Steinmeier, Paul and Hoyer, Kay-Peter and Lopes Dias, Nelson Filipe and Zielke, Reiner and Tillmann, Wolfgang and Schaper, Mirko}},
  issn         = {{2073-4352}},
  journal      = {{Crystals}},
  keywords     = {{Biomaterial, In Situ Alloying, Titanium, Additive Manufacturing}},
  number       = {{12}},
  publisher    = {{MDPI AG}},
  title        = {{{In Situ Alloying of Ti-6Al-7Nb with Copper Using Laser Powder Bed Fusion}}},
  doi          = {{10.3390/cryst15121053}},
  volume       = {{15}},
  year         = {{2025}},
}

@inproceedings{46451,
  abstract     = {{New technologies and materials carry significant potential for sustainable production and use of products. As an example, Additive Manufacturing technologies and materials promise lightweight design and energy efficient use of parts. Exhausting the full potential requires: a) consideration of uncertainties with respect to future capabilities, and b) upgradeable design guidelines to cover advancements consistently. The proposed approach merges concepts of Design-for-X with foresight algorithms of Scenario-Technique to derive actionable knowledge. It is validated by an application in the field of Additive Manufacturing, namely Metal Fused Deposition Modelling. Engineers benefit from the intuitive access to heterogeneous types of sustainability related information.}},
  author       = {{Gräßler, Iris and Mozgova, Iryna and Pottebaum, Jens and Ott, Manuel and Jung, Philipp and Hesse, Philipp}},
  booktitle    = {{17th CIRP Conference on Intelligent Computation in Manufacturing Engineering}},
  keywords     = {{Design-for-X, Scenario-Technique, sustainability, uncertainty, Life-Cycle Engineering, Additive Manufacturing, Circular Economy}},
  location     = {{Gulf of Naples}},
  pages        = {{549--554}},
  publisher    = {{Elsevier}},
  title        = {{{Handling of uncertainties in the design of sustainable Additive Manufacturing products by merging Design-for-X and Scenario-Technique}}},
  doi          = {{10.1016/j.procir.2024.08.238}},
  volume       = {{126}},
  year         = {{2024}},
}

@article{57699,
  abstract     = {{<jats:p>The optimization of process parameters in powder Directed Energy Deposition (DED) is essential for achieving consistent, high-quality bead geometries, which directly influence the performance and structural integrity of fabricated components. As a subset of additive manufacturing (AM), the DED process, also referred to as laser metal deposition (LMD), enables precise, layer-by-layer material deposition, making it highly suitable for complex geometries and part repair applications. Critical parameters, such as the laser power, feed rate, powder mass flow, and substrate temperature govern the deposition process, impacting the bead height, width, contact angle, and dilution. Inconsistent control over these variables can lead to defects, such as poor bonding, dimensional inaccuracies, and material weaknesses, ultimately compromising the final product. This paper investigates the effects of various process parameters, specifically the substrate temperature, on bead track geometry in DED processes for stainless steel (1.4404). A specialized experimental setup, integrated within a DED machine, facilitates the controlled thermal conditioning of sample sheets. Using Design of Experiments (DoE) methods, individual bead marks are generated and analyzed to assess geometric characteristics. Regression models, including both linear and quadratic approaches, are constructed to predict machine parameters for achieving the desired bead geometry at different substrate temperatures. Validation experiments confirm the accuracy and reliability of the models, particularly in predicting the bead height, bead width, and contact angle across a broad range of substrate temperatures. However, the models demonstrated limitations in accurately predicting dilution, indicating the need for further refinement. Despite some deviations in measured values, successful fabrication is achieved, demonstrating robust bonding between the bead and substrate. The developed models offer insights into optimizing DED process parameters to achieve desired bead characteristics, advancing the precision and reliability of additive manufacturing technology. Future work will focus on refining the regression models to improve predictions, particularly for dilution, and further investigate non-linear interactions between process variables.</jats:p>}},
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Gnaase, Stefan and Lehnert, Dennis and Walter, Artur and Rohling, Robin and Tröster, Thomas}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{additive manufacturing, direct energy deposition, laser metal deposition}},
  number       = {{12}},
  publisher    = {{MDPI AG}},
  title        = {{{Effect of Substrate Temperature on Bead Track Geometry of 316L in Directed Energy Deposition: Investigation and Regression Modeling}}},
  doi          = {{10.3390/met14121353}},
  volume       = {{14}},
  year         = {{2024}},
}

@article{56089,
  abstract     = {{<jats:p>Additive manufacturing (AM) technologies enable near-net-shape designs and demand-oriented material usage, which significantly minimizes waste. This points to a substantial opportunity for further optimization in material savings and process design. The current study delves into the advancement of sustainable manufacturing practices in the automotive industry, emphasizing the crucial role of lightweight construction concepts and AM technologies in enhancing resource efficiency and reducing greenhouse gas emissions. By exploring the integration of novel AM techniques such as selective laser melting (SLM) and laser metal deposition (LMD), the study aims to overcome existing limitations like slow build-up rates and limited component resolution. The study’s core objective revolves around the development and validation of a continuous process chain that synergizes different AM routes. In the current study, the continuous process chain for DMG MORI Lasertec 65 3D’s LMD system and the DMG MORI Lasertec 30 3D’s was demonstrated using 316L and 1.2709 steel materials. This integrated approach is designed to significantly curtail process times and minimize component costs, thus suggesting an industry-oriented process chain for future manufacturing paradigms. Additionally, the research investigates the production and material behavior of components under varying manufacturing processes, material combinations, and boundary layer materials. The culmination of this study is the validation of the proposed process route through a technology demonstrator, assessing its scalability and setting a benchmark for resource-efficient manufacturing in the automotive sector.</jats:p>}},
  author       = {{Chalicheemalapalli Jayasankar, Deviprasad and Gnaase, Stefan and Kaiser, Maximilian Alexander and Lehnert, Dennis and Tröster, Thomas}},
  issn         = {{2075-4701}},
  journal      = {{Metals}},
  keywords     = {{additive manufacturing (AM), selective laser melting (SLM), laser metal deposition (LMD), hybrid manufacturing, process optimization, 316L, 1.2709}},
  number       = {{7}},
  publisher    = {{MDPI AG}},
  title        = {{{Advancements in Hybrid Additive Manufacturing: Integrating SLM and LMD for High-Performance Applications}}},
  doi          = {{10.3390/met14070772}},
  volume       = {{14}},
  year         = {{2024}},
}

@inproceedings{51218,
  abstract     = {{Polymer composites represent the industry standard in injection molding for the production of plastic components with increased requirements in terms of heat resistance and stiffness. In the field of laser sintering (LS), these materials are less common so far. In order to extend the available material variety for the LS process, new ceramic-filled Polyamide 613 powders are investigated within the scope of this work. Here, the resulting properties from two different powder production methods are compared. One filled powder is produced by dry blending and the other powder with the same filler and filling ratio is produced by encapsulating the filler particles inside the polymer particles within the dissolution-precipitation process. It was found that encapsulating the filler particles can provide certain benefits for the processability, for example an improved powder flowability or better filler dispersion. However, encapsulating the filler also alters the thermal properties of the precipitated powder. }},
  author       = {{Kletetzka, Ivo and Neitzel, Fabian and Schmid, Hans-Joachim}},
  booktitle    = {{Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium}},
  editor       = {{Beaman, Joseph}},
  keywords     = {{Additive Manufacturing, Laser Sintering, Filled Materials, Composites, Polyamide 613}},
  location     = {{Austin}},
  title        = {{{Assessing the Impact of the Powder Production Method on Ceramic-filled Polyamide Composites made by Laser Sintering}}},
  doi          = {{https://doi.org/10.26153/tsw/50931}},
  year         = {{2023}},
}

@inproceedings{46862,
  abstract     = {{The high flammability of components manufactured by laser sintering (LS) using standard polyamide 12 (PA12) powder still severely restricts their use in industries such as electronics, aviation, and transportation. A key factor for the further establishment of LS is the expansion of the material portfolio with, for example, refreshable and halogen-free flame-retardant (FR) powder materials. Accordingly, various halogen-free FRs are investigated in this work and evaluated with respect to their use in LS. First, their decomposition behavior and mode of action are examined. Subsequently, the additives are dry blended with PA12 to investigate properties relevant for LS, such as particle morphology, thermal behavior and melt viscosity. Afterwards, test specimens for UL94 vertical flame-retardancy tests are produced by processing the dry blends on an EOS P3 LS system. Finally, the process stability of the process-aged powder blends is investigated by again examining the thermal behavior and melt viscosity.}},
  author       = {{Neitzel, Fabian and Kletetzka, Ivo and Schmid, Hans-Joachim}},
  booktitle    = {{Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium}},
  editor       = {{Beaman, Joseph}},
  keywords     = {{Additive Manufacturing, Laser Sintering, Flame Retardant, Polyamide 12}},
  location     = {{Austin}},
  title        = {{{Halogen-Free Flame Retardant Powder Materials for Laser Sintering: Evaluation and Process Stability Analysis}}},
  doi          = {{https://doi.org/10.26153/tsw/50926}},
  year         = {{2023}},
}

@inproceedings{48012,
  abstract     = {{3D printing is a well-established technology with rapidly increasing usage scenarios both in the industry and consumer context. The growing popularity of 3D printing has also attracted security researchers, who have analyzed possibilities for weakening 3D models or stealing intellectual property from 3D models. We extend these important aspects and provide the first comprehensive security analysis of 3D printing data formats. We performed our systematic study on the example of the 3D Manufacturing Format (3MF), which offers a large variety of features that could lead to critical attacks. Based on 3MF’s features, we systematized three attack goals: Data Exfiltration (dex), Denial of Service, and UI Spoofing (uis). We achieve these goals by exploiting the complexity of 3MF, which is based on the Open Packaging Conventions (OPC) format and uses XML to define 3D models. In total, our analysis led to 352 tests. To create and run these tests automatically, we implemented an open-source tool named 3MF Analyzer (tool), which helped us evaluate 20 applications.}},
  author       = {{Rossel, Jost and Mladenov, Vladislav and Somorovsky, Juraj}},
  booktitle    = {{Proceedings of the 26th International Symposium on Research in Attacks, Intrusions and Defenses}},
  keywords     = {{Data Format Security, 3D Manufacturing Format, 3D Printing, Additive Manufacturing}},
  location     = {{Hongkong}},
  publisher    = {{ACM}},
  title        = {{{Security Analysis of the 3MF Data Format}}},
  doi          = {{10.1145/3607199.3607216}},
  year         = {{2023}},
}

@inproceedings{36866,
  abstract     = {{Die additive Fertigung bietet die Möglichkeit, digitale Prototypen dank der
Besonderheit der werkzeuglosen Fertigung schnellstmöglich in reale Strukturen
umzusetzen. Dieses Verfahren kann jedoch nur dann mit optimaler Geschwindigkeit
genutzt werden, wenn Engpässe wirksam vermieden werden können. Einer dieser
Engpässe ist der Konstruktionsprozess. Gerade im Bereich der additiven Fertigung
sind in letzter Zeit immer leistungsfähigere Softwarelösungen erschienen, die das
Design für die additive Fertigung, einschließlich der meisten Computer-Aided-Design
(CAD)-Aufgaben, beschleunigen. In vielen Bereichen wird daher bereits versucht, so
viele Schritte wie möglich zu automatisieren, nicht selten unter Verwendung
neuronaler Netze und künstlicher Intelligenz. Dieser Beitrag zeigt am Beispiel einer
automatisierten Strukturoptimierung eines Stuhls, warum das Nutzen neuronaler
Netze im Konstruktionsprozess sinnvoll ist, um die Bereiche der konventionellen
Topologieoptimierung und des Generative Design weiter zu verknüpfen und somit die
Produktentwicklungszeit zu reduzieren.}},
  author       = {{Ott, Manuel and Meihöfener, Niclas and Koch, Rainer}},
  booktitle    = {{Bericht 407 - 7. Tagung des DVM-Arbeitskreises Additiv gefertigte Bauteile und Strukturen}},
  keywords     = {{Künstliche Intelligenz, Neuronale Netze, 3D-Druck, Design for Additive Manufacturing}},
  location     = {{Berlin}},
  pages        = {{91--106}},
  title        = {{{Neuronale Netze in der Konstruktion zur Ausschöpfung der Potentiale additiver Fertigungstechnologien}}},
  doi          = {{10.48447/ADD-2022-014}},
  volume       = {{7}},
  year         = {{2022}},
}

@inproceedings{24426,
  author       = {{Urbanek, Stefan and Pauline, Frey and Magerkohl, Sebastian and Zimmer, Detmar and Tasche, Lennart and Schaper, Mirko and Ponick, Bernd}},
  keywords     = {{Elektromotor, Elektromaschine, Additive Fertigung, AF, AM, Additive Manufacturing, DMRC, KAt}},
  location     = {{Connecticut, USA}},
  title        = {{{Design and Experimental Investigation of an Additively Manufactured PMSM Rotor}}},
  doi          = {{10.1109/IEMDC47953.2021.9449566}},
  year         = {{2021}},
}

@article{24589,
  abstract     = {{Additive manufacturing, e.g. by laser powder bed fusion (LPBF), is very attractive for lightweight constructions, as complex and stress-optimised structures integrating multiple functions can be produced within one process. Unfortunately, high strength AlZnMgCu alloys tend to hot cracking during LPBF
and thus have not so far been applicable. In this work the melting and solidification behaviour of
AlZnMgCu alloy powder variants with particle surface inoculation was analysed by Differential Fast
Scanning Calorimetry. The aim is to establish a method that makes it possible to assess powder modifications in terms of their suitability for LPBF on a laboratory scale requiring only small amounts of powder.
Therefore, solidification undercooling is evaluated at cooling rates relevant for LPBF. A method for the
temperature correction and normalisation of the DFSC results is proposed. Two ways of powder modification were tested for the powder particles surface inoculation by titanium carbide (TiC) nanoparticles:
via wet-chemical deposition and via mechanical mixing.
A low undercooling from DFSC correlates with a low number of cracks of LPBF-manufactured cubes. It
appears that a reduced undercooling combined with reduced solidification onset scatter indicates the
possibility of crack-free LPBF of alloys that otherwise tend to hot cracking.}},
  author       = {{Zhuravlev, Evgeny and Milkereit, Benjamin and Yang, Bin and Heiland, Steffen and Vieth, Pascal and Voigt, Markus and Schaper, Mirko and Grundmeier, Guido and Schick, Christoph and Kessler, Olaf}},
  issn         = {{0264-1275}},
  journal      = {{Materials & Design}},
  keywords     = {{Aluminium alloy 7075, Differential fast scanning calorimetry, Solidification, Undercooling, Additive manufacturing}},
  title        = {{{Assessment of AlZnMgCu alloy powder modification for crack-free laser powder bed fusion by differential fast scanning calorimetry}}},
  doi          = {{10.1016/j.matdes.2021.109677}},
  year         = {{2021}},
}

@phdthesis{21209,
  abstract     = {{Die additive Fertigung mittels Laser Powderbed Fusion Verfahren (L-PBF) von Metallen wird zunehmend genutzt, um Funktionsbauteile endkonturnah zu fertigen. Die in der vor-liegenden Arbeit untersuchte Parameter- und Prozessoptimierung liefert einen Beitrag zur wirtschaftlichen Nutzung des L-PBF und zeigt, dass höhere Aufbauraten bei der ganzheit-lichen Betrachtung des Prozesses realisierbar sind.
Die Parameter- und Prozessoptimierung erfordert eine Untersuchung des Einflusses der Fertigungs- und Nachbearbeitungsparameter auf das erzeugte Volumen sowie auf die Mikrostruktur und die resultierenden Materialeigenschaften. Das Ziel der vorliegenden Arbeit ist die Entwicklung einer optimierten Prozessführung mit abschließender Bewer-tung der Wirtschaftlichkeit. Mit dem entwickelten Gesamtprozess wird eine um den Faktor 1,6 höhere Aufbaurate erzielt. Des Weiteren wird die Methodik zur Erarbeitung des opti-mierten Prozessfensters beschrieben, sodass die Herangehensweise auf weitere Werk-stoffe angewendet werden kann. Die mechanischen Eigenschaften werden für den stati-schen und dynamischen Lastfall untersucht und mit der Mikrostruktur korreliert. Abschlie-ßend wird die Prozessoptimierung zur Fertigung eines Demonstrators eingesetzt und wirtschaftlich validiert. Die Ergebnisse zeigen, dass durch das hier angewendete Vorge-hen eine Prozesszeitreduktion von 22,5% und eine Kostenreduktion von 11% realisiert werden kann.}},
  author       = {{Ahlers, Dominik}},
  isbn         = {{978-3844074246}},
  keywords     = {{Additive Manufacturing, SLM}},
  pages        = {{137}},
  publisher    = {{Shaker}},
  title        = {{{Parameter- und Prozessoptimierung für den additiven Fertigungsprozess im Pulverbett am Beispiel der Legierung Ti6Al4V }}},
  volume       = {{19}},
  year         = {{2020}},
}

@phdthesis{24753,
  abstract     = {{Polymer Laser Sintering (LS) is one of the most used Additive Manufacturing (AM) technologies for the tool-less production of polymer parts. The raw material is a polymer powder which is melted layerwise by the use of laser energy. Especially for the production of single parts, small series, individualized and complex structures, the technology is yet established in few branches. However, inhomogeneous and hardly controllable thermal effects during manufacturing limit the build reproducibility. The present work focuses on temperatures within so-called part cakes, their time dependency and their influence on process quality. Therefore, a temperature measurement system is implemented into a commercial laser sintering machine. Based on the experimental data a model to simulate heat transfer within part cakes is set up. Individual thermal histories during processing are successfully correlated with position dependent powder ageing effects. Another focus is on the analysis of a recycling optimized material. First results of correlations between thermal histories and part properties are shown in order to provide an outlook to further research. The data and knowledge gained through this work can be used to understand thermal effects in greater depth and to increase the process quality via optimizations.}},
  author       = {{Josupeit, Stefan}},
  isbn         = {{978-3-8440-6720-0}},
  keywords     = {{Additive Manufacturing, Polymer Laser Sintering, Polymer Science}},
  pages        = {{178}},
  publisher    = {{Shaker Verlag GmbH}},
  title        = {{{On the Influence of Thermal Histories within Part Cakes on the Polymer Laser Sintering Process}}},
  volume       = {{11}},
  year         = {{2019}},
}