Fraunhofer Institute IAPT
Fraunhofer Institute IAPT

AM SYSTEMS

The AM Systems department develops customized solutions for smart and highly automated additive manufacturing. Concepts from quality-assured “First Time Right” production of complex batch size 1 components are developed here and realized as intelligent machine networking pursuant to Industry 4.0. The department is divided into two specialized groups in which the required technological modules are developed and implemented for industry. The service in this context encompasses development of individual system components, the linking and realization of completely autonomous process chains, and their implementation as the Additive Mobile Factory. Added to this is the mapping of process flows in a digital twin and simulation-aided optimization of production lines through a self-developed tool.

Sensors and Automation

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The goal that the Sensors and Automation Group has set itself is to develop AM production processes that are more precise and automated through specially developed sensors, calibration, and automation solutions. This enables the reduction of costs for manual interventions and manual post-processing. These developments include:

  • the development of innovative optical sensor solutions for additive and conventional processes
  • greater accuracy through sensor and system calibration
  • the development of smart-robot- and CNC-based automation solutions
  • system control through sensors and augmented reality

Directed Energy Deposition Systems

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The focus of this group is on development of highly productive Directed Energy Deposition (DED) processes and their peripheral system technology for additive manufacturing. Adapted from the coating and repair of components, this process encompasses laser powder, laser wire, and wire arc additive manufacturing technologies. This means that customized solutions can be developed to suit component and production requirements. The focus of this specialized group includes:

  • development of path planning tools for deposition welding of complex 3D structures
  • DED process development through machine learning algorithms•
  • the design and realization of location-independent and autonomous production units, including final processing of components
  • simulation-aided optimization of factory and production structures, including their mapping by a digital twin

Sample projects

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Additive Mobile Factory

AMF

The project aims to develop a hybrid process chain with different Directed Energy Deposition technologies and following machining steps. The results are used directly to establish a decentralized manufacturing solution – The Additive Mobile Factory.

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SensePRO

Objective of the project is the development of a multidirectional sensor system for robot- and CNC-based welding- and depositioning processes to enable in-process digitalization and process control. The sensor integration results in the reduction of production rejects and makes part of the post quality assurance obsolete.

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REGIS

To establish an economic manufacturing process for large-scale parts, this project investigates the joining of additively manufactured elements. Titanium parts for the aerospace industry are build up by Wire Arc Additive Manufacturing to be joined by laser welding.

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Smart4DED

The project focuses on economic and resource efficient production of Titanium aircraft components using Laser Metal Deposition (LMD) technique. Within the framework of this project, a tailored linear machine setup will be constructed and integrated with the complete process chain.

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FlexWeld

The project aims the development of a mobile Laser Metal Deposition system that uses wire to locally repair defects in injection molding tools. The remote controlled manufacturing system offers with the flexible repair process an efficient alternative to the cost intensive tool change.

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PAULA

The project focusses on the increase of 3D printing efficiency to improve applicability and profitability. The achievement of the objectives strengthens the role of Germany in the context of applications in industry 4.0 factory structures.