Metal additive manufactured, topology optimized components have already demonstrated the immense impact of weight reduction, resource efficiency, and mechanical performance. The mono-materials with homogeneous material properties are often insufficient to meet today’s heterogeneous application requirements. New multi-material components with locally tailored mechanical, electrical, thermal, or magnetic properties must be developed to meet the new and challenging requirements and significantly improve the component performance. Based on the immense potential for 3D printed multi-material components, current problems will be solved within this project and result in high-impact industrial products: Material Design, multi-material 3D printing, component design, and sustainability. These factors will be supported by numerical simulations and validated by use case experiments.
MADE-3D aims to enhance the additive manufacturing process in order to enable the multi-material processing for multi-material components with locally tailored properties to meet the challenging application requirements and improve component performance. The focus relies on material design, process design, component design, and sustainability and will be supported by numerical simulations and computational approaches. MADE-3D will utilize a lean system design approach with science-based models using Direct Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF). Besides, will investigate the circular material cycle to achieve sustainable manufacturing routes. The results of the project will significantly impact the entire process chain of 3D printed multi-material components, from computational material-design concepts to industrialization and sustainability.
Objectives
The main challenge in 3D printing is the inability to print the majority of steels and alloys without encountering issues like cracking. This challenge is amplified when attempting to print multi-material components. The lack of available combinations of multiple materials is a significant barrier to achieving progress in 3D printing. The conventional empirical approach to material development for 3D printing is expensive and time-consuming, involving extensive testing and long development cycles. Alternative approaches are needed to accelerate material design and overcome these challenges.
Additive Manufacturing technologies are improved to the state of industrialization and thus disrupt 3D printing applications.
Designers are provided with novel information on design guidelines essential to exploit the advantages of multi-material processing leading to numerous product improvements as demonstrated in this project.
Based on sustainability addressing energy efficiency, cost, and recyclability, economic decisions to industrialize multi-material components will be made.
Results
Initial Communication Kit
Made-3D Leaflet
Roll-up
Made-3D Press Release
Deliverable D2.2 Building and application of microscale simulation
Deliverable D3.1: Baseline powder: 100 kg FeSi/316L; 80kg Ti; 130kg IN718; 50 kg AlSi10Mg; 100kg CuCrZr
Deliverables D3.4: Spreading of bi-materials Interaction of the Al and Cu powders in the vicinity of parts
Made-3D Poster
Advanced Current Measurement Sensor Enabled by
Multi-Material Additive Manufacturing
Publication:
Rocket Engine Vacuum Nozzle 3D Printing Manufacturing, Weight, and Cost Savings
Publication:
Multi-material laser powder bed fusion: The effect of crosscontaminations of Cu particles in AlSi10Mg feed
Publication:
Additive Manufacturing in the Production of Rocket Propulsion
System Components
Publication:
Multi-material 3D printing of vacuum nozzle of rocket engine:
design, manufacturing, weight, and cost savings
Publication:
Influence of processing parameters on mechanical properties of multi-material components from aluminium and copper – manufactured by laser-based powder bed fusion
Publication:
Multi-material laser powder bed fusion: the effect of crosscontaminations of cu and al particles in asi10mg and cucr1zr feedstock on the mechanical properties of the part
Publication:
Multi-Material Powder Bed Fusion – Chances and Challenges