Additive manufacturing has gained a firm foothold in industrial practice. It is unfolding its potential in more and more sectors and manufacturing processes. The organizers of Intec, Z and GrindTec are taking the growing importance of this key technology into account with the special show and specialist forum "Additive Manufacturing - Evolution of a Modern Technology". The format invites visitors to the halls of Leipziger Messe from March 7 to 10, 2023 as part of the international trade fair network. The focus will be on current applications as well as promising ideas and solutions for the tasks of tomorrow. They will be presented by users, developers and researchers from corporations, medium-sized companies and scientific institutions. In terms of content, the presentations and exhibits will focus on the requirements that users of additive technologies have particularly in mind: Flexibility, reliability, cost-effectiveness and sustainability.

First fully automated metal 3D printing lines for automotive series production

End-to-end digitalized and automated processes are essential for achieving these goals in series production. The results of IDAM - Industrialization and Digitalization of Additive Manufacturing - provide proof of this. The twelve partners in this project, which is funded by the German Federal Ministry of Education and Research and led by BMW, have succeeded in setting up digitally networked and fully automated 3D printing production lines and preparing them for series production of metal components in the automotive industry for the first time. The systems can be used to cost-effectively produce around 50,000 components per year in the production of identical parts and more than 10,000 individual and spare parts using laser powder bed fusion.

Maximilian Binder, BMW Group, Munich, will talk about the successful industrialization of metallic 3D printing in the project in his keynote speech at the start of the specialist forum "Additive manufacturing - evolution of a modern technology" as part of the Intec, Z and GrindTec 2023 trade fair alliance.

Important building blocks on the path from isolated individual production steps to end-to-end production were developments for innovative concepts for the automatic generation of 3D print data, for the automatic transport of mobile build chambers between the modules of the IDAM production lines and for fully automatic inline quality assurance.

Metal 3D printing for SMEs: contradiction or perfect complement?

Additive manufacturing also demonstrates its advantages when it comes to the production of individual workpieces or small batches. Hans-Werner Theobald, founder and owner of 3D-Metall Theobald e. K. Leipzig, will shed light on the conditions under which this makes sense in his presentation "Metal 3D printing for SMEs: contradiction or perfect complement?". "It's a misconception that a part to be additively manufactured has to be topologically optimized beforehand," says the trained industrial mechanic, graduate industrial engineer and Master of Business Administration, dispelling a preconception. "Many existing components can be sensibly additively manufactured with little or no adaptation. This applies in particular to thin-walled, geometrically complex workpieces that require many processing steps in conventional production and for which tools and clamping devices must first be manufactured. With metallic 3D printing such as selective laser melting, it is possible to manufacture such parts without tools, saving time and materials. This increases flexibility and saves costs."

The metal 3D printing company produces such components from batch size 1 to small series of around 100 pieces for machine and apparatus construction, special systems, operating equipment in the automotive supply industry, injection molding and stamping tools or prototype construction in medical technology, among others. Hans-Werner Theobald will present some examples of applications both in his lecture and at the special show. "We are particularly looking forward to the opportunity to present ourselves again as an exhibitor in direct contact with visitors. In the past, Intec and Z have been an important platform for our small company to acquire new customers."

Decision support for technology selection

Companies that want to use 3D printing solutions in their production are often faced with the question of which technology to choose. Florian Grabs from IGO3D GmbH in Hanover will answer this question in his presentation "Desktop or industrial machine? A decision-making aid with best-practice examples from companies". IGO3D advises and supports both large companies and small and medium-sized enterprises in the integration of additive technologies. "It is important to be clear in advance which materials you want to print in which quantities and what process stability is required. Another decision criterion is how intensively the user is familiar with the possibilities of the technology. We provide advice and training on all topics relating to the use of additive processes," explains Florian Grabs, coordinator for the industrial sector at IGO3D.

The company is a distributor of 3D products such as scanners, software, printers and materials and is primarily active in the DACH region (Germany, Austria, Switzerland). It offers technologies for additive manufacturing with plastics, metals, wood, ceramics, silicones and many other materials.

Additive flexibility and highly productive machines combined

Additive manufacturing also enables completely new production solutions in the textile industry. Michael Kieren, Business Development Manager at textile machinery manufacturer Karl Mayer, will be presenting an innovation in this field. In cooperation with Bielefeld University of Applied Sciences, the company has created a 3D printing table that can be directly integrated into textile series production. "We are combining the flexibility of additive technology with the high productivity of textile machines. The inline print head can be quickly moved to any textile production position and apply various applications such as partial reinforcements, design or functional elements. Pattern recognition software and a camera system ensure that this always happens at the right position. This makes it possible to manufacture individualized products in a highly productive series process," says Michael Kieren, describing the innovation.

The partners have tested their development in the production of footwear fabrics. "A wide variety of applications are needed here more than in other areas. The 3D printing table is very well suited to this. The prototype is ready. We are now working with potential users to put the process into practice," says Michael Kieren, referring to the next steps.

Additively manufacturing new products from residual materials

One advantage of additive technologies compared to subtractive processes is the more efficient use of materials. Parts are built up contour by contour, layer by layer, instead of from a solid block of material. The partners are aiming for even greater sustainability in the SAMSax project, which was launched in April 2022. The term stands for Sustainable Additive Manufacturing in Saxony. "Our aim is to process residual materials from industry and agriculture for additive manufacturing and use them to produce new products. We want to pave the way for an end-to-end circular economy," explains Dr. Lisa Kühnel from the Chair of Additive Manufacturing at TU Bergakademie Freiberg. The Freiberg scientists have been working on additive manufacturing based on bio-based materials and residues for some time now. Among other things, they have produced elements for sound and heat insulation from miscanthus reeds. Crushed sand ground into powder can also be used additively.

Together with partners from TU Chemnitz and TU Dresden, researchers at TU Freiberg are setting up a real-world laboratory for sustainable additive manufacturing in SAMSax. "We want to test and visualize the possibilities that additive technologies offer for the innovative use of waste and residual materials. This will also open up new business areas for Saxon industry. We see good opportunities here, especially for small and medium-sized companies. That's why we look forward to receiving many suggestions from business practice," emphasizes Dr. Kühnel, who will present initial results and other SAMSax projects in her presentation at the Intec, Z and GrindTec 2023 trade fair alliance.