Multi-material AM based on powder-bed and extrusion processes

Multi-material AM based on powder-bed and extrusion processes

Duration: 31 December 2024 – 31 December 2027
Funding: German Research Foundation (DFG)

Project management

Prof. Dr.

Ingo Reinhold

Field of appointment: Coating processes

Section:: FM
Phone:: +49 341 3076-2355

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Large-scale equipment for multi-material additive manufacturing (3D printing)

Presentation of various additive manufacturing processes and testing procedures for materials and components — Figure 1: HTWK Leipzig infrastructure for multi-material AM (Image: HTWK Leipzig)

Schematic cross-sectional view of a multi-material system featuring various porous structures, sensors and access points for different functions — Figure 2: Multi-material approach for the hybrid integration of different functions (Image: HTWK Leipzig)

AI-generated collage of modern applications of additive manufacturing in sectors such as medicine, energy, electronics and mobility — Figure 3: Areas of application (images generated by AI using firefly.adobe.com)

Additive manufacturing (AM) has the potential to revolutionise engineering. Through its fundamental and application-oriented research focusing on multi-material AM, HTWK Leipzig is making a significant contribution at both national and international level.

Through cross-faculty collaboration, scientific research is conducted on issues across the additive manufacturing process chains. Research findings and infrastructure are utilised in a transdisciplinary manner (see Figure 1) to develop the fundamentals and new fields of application for various AM technologies, including DIGITAL PRE-PRESS, MATERIALS, HYBRID ADDITIVE MANUFACTURING PROCESSES, POST-PROCESSING and QUALITY MANAGEMENT.

The multi-material approach goes beyond mere structural design and enables the integration of sensory and actuator functions into 3D-printed structures (Figure 2). By processing functional materials with sensory, optical and biological properties, we can create unique material combinations that cannot be achieved using conventional methods.

Additively manufactured multi-material systems show great promise for future applications in construction, lightweight engineering, interior design and in the fields of production engineering, electronics, the healthcare sector, (regenerative) medicine, energy, mobility and medical technology. Functionalised components can serve as data interfaces for diagnostics (online monitoring), support digitalisation or enable time-dependent behaviour. As industry faces challenges such as cost efficiency, material savings and decentralised manufacturing with a less skilled workforce, multi-material additive manufacturing will play an increasingly important role in industrial applications. (Figure 3)

Research into printed heterogeneous material systems and their implementation represents a decisive step forward in additive manufacturing technology. By applying these findings to new products and applications, we can create economic value that goes beyond the gain in knowledge and secures the technological leadership of local industry.

More on the Multimaterial AM research area