Efficient additive Manufacturing of Multi-Material Components

During the first funding period of the CRC 814 polymeric multi-material parts with simple geometries using different powder materials were realized by means of Simultaneous Laser Beam Melting (SLBM). The so far achieved material combinations are thermoplastic amide-based elastomer (TPE-A) with polyethylene (PE-HD) or polypropylene (PP) respectively, polyethylene with polypropylene and polypropylene with polyamide-12 (PA12). Since these materials do not possess adhesion compatibility, a mixed border zone is necessary in order to establish undercuts which allow a mechanical durable interconnection (see picture).Therefore, the border zone was managed by turbulent mixture of both powders at the separation blade of the multi-chamber wiper during the deposition process. Moreover, the powder layer deposition at room temperature using vibration-controlled powder nozzles was demonstrated successfully and characterized. This new deposition method will be integrated into the SLBM process in order to realize arbitrary powder patterns for more complex components geometries as well as defined undercuts to sort out their influence on the border zone strength. Therefore, the behavior of the temperature-dependent flowability of the powders at process temperatures will be analyzed and adapted to the process by powder modifications. Thus, the current aim of the part project is the realization of three-dimensional multi-material parts with arbitrary geometries and high strength using SLBM of polymers.

Professor Schmidt


Dr.-Ing. Stephan Roth
Bayerisches Laserzentrum
Konrad-Zuse-Straße 2-6
91052 Erlangen
s.roth@blz.org

Prof. Dr.-Ing. Michael Schmidt
Lehrstuhl für Photonische Technologien (LPT)
Friedrich-Alexander-Universität Erlangen-Nürnberg
Konrad-Zuse Straße 3/5
91052 Erlangen
michael.schmidt@lpt.uni-erlangen.de

Dr. rer. nat. Thomas Stichel
Bayerisches Laserzentrum
Konrad-Zuse-Straße 2-6
91052 Erlangen
t.stichel@blz.org

Thomas Schuffenhauer, M.Sc.
Bayerisches Laserzentrum
Konrad-Zuse-Straße 2-6
91052 Erlangen
t.schuffenhauer@blz.org