TY - CONF AB - 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. AU - Gräßler, Iris AU - Mozgova, Iryna AU - Pottebaum, Jens AU - Ott, Manuel AU - Jung, Philipp AU - Hesse, Philipp ED - Teti, Roberto ID - 46451 KW - Design-for-X KW - Scenario-Technique KW - sustainability KW - uncertainty KW - Life-Cycle Engineering KW - Additive Manufacturing KW - Circular Economy T2 - Procedia CIRP ICME TI - Handling of uncertainties in the design of sustainable Additive Manufacturing products by merging Design-for-X and Scenario-Technique ER - TY - CONF AB - 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. AU - Neitzel, Fabian AU - Kletetzka, Ivo AU - Schmid, Hans-Joachim ED - Beaman, Joseph ID - 46862 KW - Additive Manufacturing KW - Laser Sintering KW - Flame Retardant KW - Polyamide 12 T2 - Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium TI - Halogen-Free Flame Retardant Powder Materials for Laser Sintering: Evaluation and Process Stability Analysis ER - TY - CONF AB - 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. AU - Kletetzka, Ivo AU - Neitzel, Fabian AU - Schmid, Hans-Joachim ED - Beaman, Joseph ID - 51218 KW - Additive Manufacturing KW - Laser Sintering KW - Filled Materials KW - Composites KW - Polyamide 613 T2 - Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium TI - Assessing the Impact of the Powder Production Method on Ceramic-filled Polyamide Composites made by Laser Sintering ER - TY - CONF AB - To ensure uniform documentation of support structure information, a concept is presented that enables a standardized depiction of support structures in technical drawings based on ISO 128-3. To this end, requirements for a uniform depiction are defined and a procedure for drawing entry is presented. The drawing entry should contain all production-relevant support structure information. The standardized documentation of support structure information in technical drawings is intended to ensure a simple, clear and safe exchange of information between business units or different companies along the value chain. As a result a possible drawing entry of support structures was developed. To distinguish between different support structure types, a standardized depiction of geometrical information in a specification field is shown. The specification field gives a detailed description of the support structure type, the geometry as well as the connection to the part and the building platform. Also uncommon support types like lattice structures or CAD based support structures can be implemented. To ensure the usability the depiction is editable and extendable. AU - Lammers, Stefan AU - Koers, Thorsten AU - Magyar, Balázs AU - Zimmer, Detmar AU - Lieneke, Tobias ID - 46745 KW - additive manufacturing KW - support structures TI - Depiction of support structures in technical drawings ER - TY - CONF AB - 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. AU - Ott, Manuel AU - Meihöfener, Niclas AU - Koch, Rainer ID - 36866 KW - Künstliche Intelligenz KW - Neuronale Netze KW - 3D-Druck KW - Design for Additive Manufacturing T2 - Bericht 407 - 7. Tagung des DVM-Arbeitskreises Additiv gefertigte Bauteile und Strukturen TI - Neuronale Netze in der Konstruktion zur Ausschöpfung der Potentiale additiver Fertigungstechnologien VL - 7 ER - TY - CONF AU - Urbanek, Stefan AU - Pauline, Frey AU - Magerkohl, Sebastian AU - Zimmer, Detmar AU - Tasche, Lennart AU - Schaper, Mirko AU - Ponick, Bernd ID - 24426 KW - Elektromotor KW - Elektromaschine KW - Additive Fertigung KW - AF KW - AM KW - Additive Manufacturing KW - DMRC KW - KAt TI - Design and Experimental Investigation of an Additively Manufactured PMSM Rotor ER - TY - JOUR AB - 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. AU - Zhuravlev, Evgeny AU - Milkereit, Benjamin AU - Yang, Bin AU - Heiland, Steffen AU - Vieth, Pascal AU - Voigt, Markus AU - Schaper, Mirko AU - Grundmeier, Guido AU - Schick, Christoph AU - Kessler, Olaf ID - 24589 JF - Materials & Design KW - Aluminium alloy 7075 KW - Differential fast scanning calorimetry KW - Solidification KW - Undercooling KW - Additive manufacturing SN - 0264-1275 TI - Assessment of AlZnMgCu alloy powder modification for crack-free laser powder bed fusion by differential fast scanning calorimetry ER - TY - THES AB - 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. AU - Ahlers, Dominik ID - 21209 KW - Additive Manufacturing KW - SLM SN - 978-3844074246 TI - Parameter- und Prozessoptimierung für den additiven Fertigungsprozess im Pulverbett am Beispiel der Legierung Ti6Al4V VL - 19 ER - TY - THES AB - 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. AU - Josupeit, Stefan ID - 24753 KW - Additive Manufacturing KW - Polymer Laser Sintering KW - Polymer Science SN - 978-3-8440-6720-0 TI - On the Influence of Thermal Histories within Part Cakes on the Polymer Laser Sintering Process VL - 11 ER -