Long process times, high manufacturing costs and post-processing are often still the hurdles in 3D printing. At the joint stand "Lightweight construction from Baden-Württemberg" at Formnext in Hall 12.0, Stand D95, companies and start-ups will be demonstrating how these challenges can still be overcome and how components can be produced and optimized more quickly. The topics range from functional integration during engineering to precise post-processing after printing. And where additively manufactured components reach their limits, the companies also have a solution ready.

The right engineering is of the utmost importance in additive manufacturing: CADFEM supports developers with its simulation software in optimizing components so that fewer misprints occur and there are almost no more rejects, which reduces costs.

Before it comes to printing, the question of the right material arises: Rosswag Engineering was the first manufacturer of metal powders for additive manufacturing to receive certification from TÜV Süd. Thanks to the in-house process chain, including in-house powder atomization, a complete AM material qualification can be carried out within a few weeks in order to provide new metal materials according to the respective requirements. The start-up Q.big 3D is presenting a large-capacity 3D printer it developed itself, which can be used to produce large-volume components particularly quickly and economically. The highlight: the nozzle diameter can be varied during printing and granulate is used instead of filament. For example, outer surfaces can be printed with a fine nozzle diameter, while the inner structure of a component can be produced with a larger diameter to save time and therefore costs, which can ensure greater stability in the component.

Overcoming boundaries

Where tolerances and the surface quality of additively manufactured components are not sufficient, MiMplus Technologies can provide a remedy with the MIM process: Here, classic plastic injection molding is transferred to the world of metals and components with complex geometries can be produced in a wide variety of materials using metal powder injection molding. With the AddCasting process, Schübel offers a cost-effective way of producing even small series of metal components with complex geometries such as undercut areas. Instead of a wax part, the model of the component is 3D-printed from plastic. This model can then be used to produce further parts with the same geometry using investment casting - which is significantly faster than "classic" metal 3D printing and completely eliminates the need for upstream toolmaking.

Inpeca is part of the Böllinger Group and produces prototypes of highly complex components - this allows new tools to be tested and optimized more quickly and shortens the time to market. The parts often have to be reworked because they are not yet "finished" when they come out of the printer. Burgmaier Technologies combines its process knowledge from the subtractive machining of workpieces with additive manufacturing in order to be able to offer a component from a single source. Precise post-processing of the printed parts enables high quality requirements to be met in terms of dimensional accuracy and surfaces. Fabrikado GmbH presents the new version of its revised webshop for metal and plastic parts. There you can simply upload CAD models of components, choose between 3D printing, cutting and machining processes for production as well as various materials - and the price is calculated immediately at every step.

Formnext: Leichtbau BW, Hall 12.0, Stand D59