Additively manufactured silencers

Development and validation of additive manufacturing strategies for the implementation of effective absorber structures in pipe and housing components whilst preserving function and geometry

Duration: 15 April 2020 – 14 October 2022
Funding: Federal Ministry for Economic Affairs and Climate Action (BMWi), Central Innovation Programme for Central Germany (ZIM)

Project management

Prof. Dr.-Ing.

Fritz Peter Schulze

Chair of Production Engineering, Machine Tools, Hydraulics/Pneumatics, Computer Aided Manufacturing

Section:: FING
Phone:: +49 341 3076-4142

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Integrating noise-absorbing systems directly into housing and duct structures using 3D printing

Color-coded simulation of an additively manufactured muffler — Additive acoustic structures are used in the industrial and automotive sectors (Image: Gesellschaft für Akustikforschung Dresden mbH)

Fitting noise-emitting systems with effective sound attenuation or insulation is becoming increasingly difficult using conventional methods, given the ever-more restrictive space and integration requirements. The direct integration of sound absorbers into housing components or duct walls offers entirely new possibilities in this regard. The project aims to demonstrate solutions for this using additive manufacturing processes for the first time. The objective is to integrate acoustically highly effective absorber structures directly into specified housing and duct designs using additive techniques, without compromising their primary functional or design characteristics. To this end, the project aims to establish the technological requirements of additive manufacturing processes for the acoustic design and sound-insulation-optimised production of components, derive novel sound-damping, sound-insulating and combined absorber structures from these, and validate them using exemplary housing and duct components. If successful, this will subsequently open up numerous applications and a huge market potential. Examples include applications in the field of occupational safety for machine operators or comfort improvements in connection with e-mobility.

The project draws on existing expertise, primarily from the fields of design & development and additive manufacturing. Here, the acoustically effective structures are developed in close collaboration with the Dresden Acoustics Research Society (AED) and manufactured in the form of various prototype components. These are then measured at AED on various acoustic test benches; the results in turn can be used to derive requirements for structural development and manufacturing. The key question here is: “Can effective structures be built and put into practical use, and if so, how, and with what level of acoustic and manufacturing efficiency?” A comparison with established sound-absorption measures must not be shied away from, in order to keep the substantive relevance of the project firmly in mind.