More visibility for the AM science community

"We want to make the rapid.tech 3D scientific community even more visible. That's why we organized a poster session alongside the specialist forum last year and showed selected contributions there. We are continuing this this year. Here, 15 other candidates who took part in this year's call for papers will have the opportunity to present their research results. They can present their work in an informal atmosphere, exchange ideas with visitors, congress speakers and exhibitors and make contacts," explains Dr. Stefan Kleszczynski, acting head of the Chair of Manufacturing Technology at the Institute of Product Engineering at the University of Duisburg-Essen and member of the rapid.tech 3D advisory board. He points out that the publication partnerships with the Springer Nature Journal "Progress in Additive Manufacturing" and the RTe Journal, which were launched in 2024, will also be continued, further increasing the international appeal of rapid.tech 3D. "This motivates young scientists in particular to present their research work in Erfurt," emphasizes Dr. Kleszczynski.

Degree of innovation as a selection criterion

The selection of contributions for the publications as well as for the presentation slots is subject to a review process: In a scientific review process, leading experts in German AM research evaluated the submitted papers. The contributions with the highest degree of innovation rated by the experts received one of the eight presentation slots in the expert forum. "Our aim is to address the latest work in basic research as well as to present projects with high industrial relevance. This allows us to offer 3D printing research in the balancing act between applications that are already possible today and the potential of tomorrow," says Dr. Kleszczynski.

New approaches in antenna production

Research into the additive manufacturing of high-frequency quadrupoles, a key component in linear particle accelerators, at the University of the Federal Armed Forces in Munich has practical relevance. Research associate Stefan Brenner reports on how a prototype was produced for the first time using multi-material laser powder bed fusion. The integration of different materials in just one production step is not conventionally possible and opens up new avenues in antenna production.

Data-driven strategy to overcome the certification bottleneck

In many areas, certification processes are the "bottleneck" for efficient, scalable production. For additively manufactured aircraft components, Wolfram Groh, research assistant at TU Dresden, presents a data-based certification approach that uses machine learning algorithms and achieves results faster than previous procedures. The approach is transferable to other areas.

Additive manufacturing of wear-resistant tool components

The potential of laser-based powder bed fusion of tungsten carbide-nickel composites for the additive manufacturing of wear-resistant tool components is demonstrated by Leon Engelhardt, research associate at the Rheinische Hochschule Köln. In combination with sinter-HIP (pressure-assisted sintering), it is possible to produce dense, wear-resistant components with high strength and complex designs.

New measuring method for temperature monitoring during metal laser melting

Hanna Schönrath, research associate at the University of Duisburg-Essen, presents a novel approach to in-situ temperature determination during laser-based powder bed fusion of metals using phosphorus thermometry. The new measuring method enables improved monitoring of temperature cycles in additive manufacturing processes.

New polymers for additive manufacturing

New materials for additive manufacturing are the focus of the presentations by Simon Cholewa, research assistant at the University of Erlangen-Nuremberg, and Paul Roumeliotis, PhD student at the same institution. Simon Cholewa will provide information on the advantages and disadvantages of polybutylene terephthalate as a new material for laser powder bed fusion of polymers. It enables stiff, functional components, but exhibits brittle fracture behavior and narrow process limits.

Paul Roumeliotis presents a new flame retardant system for polyamide 12 in selective laser sintering. LOI tests, which describe the fire behavior of plastics, confirm the effectiveness of the flame retardant system, with increasing additive levels leading to improved flame retardancy.

Focus on sinter-based additive manufacturing and material extrusion printing

The potential of sinter-based additive manufacturing processes and material extrusion printing will be presented by David Stachg, research assistant at the Hamburg University of Applied Sciences, and Verena Witt, process engineer at New AIM 3D GmbH Rostock, a spin-off of the University of Rostock.

David Stachg reports on the properties of components manufactured using the sinter-based processes Cold Metal Fusion (CMF) and Metal Fused Filament Fabrication (MFFF). The research results demonstrate the development of a component design that enables "first time right" and thus unlocks the economic and sustainable potential of these processes.

Verena Witt presents a new approach to reducing anisotropic, i.e. direction-dependent, material behavior during material extrusion printing. It helps to further improve the mechanical properties of additively manufactured plastic components.

Various forums

In addition to the science forum, other forums at the rapid.tech 3D congress will provide insights into the latest AM developments and applications. On the first day, the VDMA AM4industry Forum and the Aerospace Forum will invite visitors to join the Science Forum. On the second day, the Chemistry & Process Engineering, Electronics & Components and Mobility forums are on the agenda. Software, AI & Design, Energy Technology & Hydrogen and "Innovations in AM" are the forums on the final day.

Presentations and exchange

Product and service demonstrations as well as discussions in small groups are the focus in Hall 2 - individually at the exhibitors' stands or on guided Technical Deep Dives tours, at "expert tables" and at the AM Science Poster Session directly in the hall.

The 3D Pioneers Challenge also provides inspiration for new applications of additive and digital technologies. The international competition is coming to rapid.tech 3D for the tenth time this year. The anniversary show gives all previous finalists and winners the chance to face the jury once again and thus become the "Pioneer of the Decade".