The automation and reduction of manual work steps are also highlighted in exhibits for handling and processing geometrically complex or highly delicate base structures, as well as a technology for in-situ smoothing of plastic components.
 

Minimal effort for machine vision in quality assurance

Fraunhofer IAPT accelerates and simplifies the quality assurance of additive manufacturing (AM) with an innovative combination of machine vision and cost-effective camera systems. A simple camera and AI-based evaluation of image data replace the previously required highly specialized sensors.

The labor-intensive production of comprehensive, real images for training the artificial intelligence is also eliminated. Instead, Fraunhofer IAPT generates and utilizes synthetic data. This approach accelerates the availability of AI models for image analyses and AI-supported recognition and evaluation of objects in real-time without compromising quality.

The solution takes over relevant steps of quality assurance, such as measuring objects or identifying defects. However, the application areas extend beyond quality assurance. Another example is identifying and sorting components within the automation of the process chain.
 

Universal gripping system brings flexibility to the automation of AM processes

Manufacturing companies typically utilize additive manufacturing for components in small quantities and frequently varying geometries. The large variety of shapes and objects significantly restricts the use of conventional automation solutions for AM. A new geometry-independent gripping system from Fraunhofer IAPT lifts these limitations: it handles a wide range of components—whether complete build platforms, complex geometries, or delicate structures. This flexibility enables, for example, the needs-based use of collaborative robots along the AM process chain.

The flexible gripping system allows the automation of manual work steps economically, even for small series and individual parts. Additionally, costly safety systems and restricted areas are unnecessary due to the human-centered use of collaborative robotics.
 

Automated processing of delicate structures

The development of additive processes for geometrically complex and delicate structures of any size is one of the specializations of Fraunhofer IAPT. At Formnext, the institute presents the additive reinforcement of a forged base structure for the production of a Metal Leading Edge to protect CFRP turbine blades.

In the manufacturing process, Fraunhofer IAPT takes a forged base structure and applies additional material using the DED-LB/P process on the narrow edge of the Metal Leading Edge. The precise placement of the material, the correct angle, and the exact application of energy require a complex processing strategy and precise control of the process. The experts at Fraunhofer IAPT have implemented a synchronized 8-axis movement with proprietary process and path planning software. This approach guarantees the reliable application of the titanium alloy while eliminating any damage to the delicate component.

Fraunhofer IAPT specializes in handling delicate large structures enabling the hybrid production of the leading edge. The hybrid production results in savings of more than half the titanium alloy required in purely conventional production. In addition to material savings, hybrid production also reduces tool wear and post-processing efforts.
 

Automated post-processing as part of the printing process of plastic components

Fraunhofer IAPT presents an innovation for the automated post-processing of plastic components. The technology can be integrated into existing FDM printers and smooths the surface of the component in-situ—meaning during production. By eliminating post-processing, the overall manufacturing duration can be reduced by up to 50%. Savings of up to 80% can be achieved per component.
 

From research to industrial value creation

Fraunhofer IAPT showcases its developments at Formnext 2025 along an automated AM process chain. Experts from various technology and competence fields will answer individual questions throughout the duration of the trade fair.

Beyond the technical innovations of Fraunhofer IAPT, the Fraunhofer High-Performance Center IAMHH® will also be presented at the Fraunhofer IAPT booth. Its goal is to translate research results in the field of additive manufacturing into industrial value creation. Transfer paths include the training of specialists, the provision of AM infrastructures, support for start-ups, and direct, bilateral contract research with end users.

Free tickets for Formnext 2025 are available at marketing@iapt.fraunhofer.de.