ADDITIVE

MANUFACTURING
THE PATH TOWARD
INDIVIDUAL
PRODUCTION

www.technologieland-hessen.de
  CONTENT

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 Foreword . ................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. Introduction: Additive Manufacturing – potentials within the context of the 4th

industrial revolution – the vision .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. Additive Technologies and Manufacturing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Fundamental Principles and Procedures .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Data Generation and the Additive Manufacturing Process Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Process Chains integrating Additive Manufacturing Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3. The Creation of Added Value with Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.1 Market Assessment .. ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Qualitative Economic Feasibility Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Application Scenarios and Industries .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4 3D Print Service Providers and Content Platforms .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Legal Issues in the context of Additive Manufacturing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4. Additive Fertigung:
Additive Manufacturing: Selected success stories, potentials and projects from Hessen . . . . . . . . . . . . 62
4.1 Mittelhessen University of Applied Sciences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Kegelmann Technik GmbH .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 EDAG Engineering GmbH .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4 Heraeus Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.5 FKM Sintertechnik GmbH ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.6 sauer product GmbH ............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.7 IETEC Orthopädische Einlagen GmbH Produktions KG .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.8 Philipps University of Marburg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.9 Technische Universität Darmstadt .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.10 Fraunhofer LBF . ....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.11 Hochschule für Gestaltung Offenbach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.12 FRAME ONE ............................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.13 University of Kassel ................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.14 Tatcraft GmbH . ........................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.15 Fraunhofer IGD . ....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.16 Fiberthree GmbH . ................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.17 Continental Engineering Services GmbH .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5. Overview
5.1 Hessian Companies and Research Institutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2 Literature ................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Legal Notice ............................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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 FOREWORD


W e a re e xp e c t i ng num e r o us
n e w b u s i ne s s i de as r e l at i ng
to a d d i ti ve m a nuf ac t ur i ng . I n t he
hi g h - te c h s ta te o f H e s s e n, yo u w i l l
fin d a ti g h t c om p e t e nc e ne t w o r k. “

Tarek Al-Wazir
Hessian Minister of Economics, Energy,
Transport and Housing

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With additive manufacturing processes, single-unit pro-
duction can be achieved at prices which can already
compete with classic mass production: the hearing aid
adjusted to an individual ear canal, replacement parts for
vintage cars – these are a few examples of where additive
manufacturing has already established itself. It is particu-
larly suitable for products with complex geometry. Its
big advantage is the efficiency of resources. Unlike with
material cutting, material is not removed until only the
desired shape remains. With 3D printing, the material is
only applied where it is required. This means that there
is no excess.
This technology is developing at great speed and still
shows a great deal of promise. It isn’t just system manu-
facturers who are benefiting from the high sales figures,
but also material producers and service providers. Big
opportunities are presenting themselves to new players.
Since the arrival of the first additive manufacturing tech-
nologies in the mid-90s, several pioneers of innovation
in Hessen have made a name for themselves. For years,
one of the world’s leading fairs in this area has been held
in the trade-fair city of Frankfurt. Large Hessen material
manufacturers are currently entering the market.
We hope that this brochure gives you some food for
thought for innovative plans and new business ideas. And
we would be delighted if you should allow us to support
you in implementing your ideas.
Yours,
Tarek Al-Wazir
Hessian Minister of Economics, Energy,
Transport and Housing
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 1.  INTRODUCTION:
 DDITIVE MANUFACTURING – POTENTIALS
A
WITHIN THE CONTEXT OF THE 4TH
INDUSTRIAL REVOLUTION – THE VISION
The development of additive manufacturing procedures
(AM for short) in the 1980s made important contributions
to the groundwork for the next, the fourth, industrial rev-
olution. While the first industrial revolution in the second
half of the 18th century refers to the transfer of manual
activities into mechanised processes using water and
steam power, the second industrial revolution made it
possible to mass-produce with divided responsibilities
at electrically operated assembly lines. The third big
development leap for industrial processes was the use
of information technologies to automate production. The
intelligent organisation of decentralised production units
by linking information and production technology via the
Internet of Things will offer the foundation for the fourth
industrial revolution where experts see great potential
for the German economy among the global competition.
It is expected that in the future, customers will be able
to purchase a product via internet portals which can
access, modify and archive data for components as well
as monitor the status of a production order. The manu-
facturing process with decentralised production units
will be carried out in an effective location according to
the spatial location of the customer and the equipment
available at the production units. The products themselves
will not be sent around the globe, just the data for their
6
manufacture – which can be customised well into the
production process. The digital factories will no longer
only be located in the Far East; instead, they will consist
of regional decentralised production units which make
it possible to offer ‘individual items from the assembly
line’ at prices comparable with mass-produced items.
Products, machinery and transport boxes are linked with
the web via microchips. The Internet of Things will allow
the self-organisation of intelligent production procedures
and increase productivity by up to 50 percent. In addition,
the storage of raw material information in the product
will promote recyclability and enable closed material
cycles. Here, experts estimate a medium-term energy and
resource savings potential of around 20 to 25 percent.
The additive manufacturing process is expected to play a
crucial role in the context of the fourth industrial revolution.
The generative nature of these technologies complete-
ly revises the previous understanding of conventional
material-cutting techniques such as milling, drilling or
turning. Here, it is not just a case of saving resources
and avoiding production waste; it is possible to produce
product parts with the kind of complex geometries which
would not be possible at all if conventional methods such
as casting were used.
Experts assume that generative manufacturing will first
establish itself as an addition to the existing production
processes. Already today though, the large number of
small-scale company foundations brought about by the
further development of additive manufacturing processes
is striking. Operating mini factories with new business
models and unique products has been made possible
by 3D printing entrepreneurs in almost all larger cities.
These entrepreneurs were also able to find the necessary
capital on the internet and social media using Crowd-
funding campaigns (Cf. Horsch, Florian: 3D-Druck für
alle – Der Do-it-yourself-Guide. [3D Printing for Everyone
– The Do-It-Yourself Guide] Munich, Vienna: Carl Hanser
Verlag, 2014).
“There will be plenty of niches”, says internet visionary
Chris Anderson as he looks to the future of 3D printing.
“We will just be seeing more of everything: more innova-
tion in more locations from more people concentrating
on smaller niches. As a whole, all these new products
will reinvent the industrial economy, often with just a
few thousand pieces each time, but these will be exactly
the right products for the increasingly demanding con-
sumer.” (Source: Anderson, C.: Makers. Das Internet der
Dinge: die nächste industrielle Revolution. [The Internet
of Things: The Next Industrial Revolution] Munich, Vienna:
Carl Hanser Verlag, 2013)
This development also appears attractive to countries
which have permitted an enormous reduction of industrial
production to make room for the service sector over the
last few decades. Additive manufacturing technologies
are recognised and perceived as the key for the re-in-
dustrialisation of national economies.
In his State of the Nation speech in February 2013, former
US president Barack Obama described additive manufac-
turing as the foundation for a new growth in US production.
In total, the White House set aside a billion US dollars
to promote the American economy and established a
network of support institutions for this. With the research
programme Horizon 2020, the European Commission
wishes to support the expansion of additive manufactur-
ing in Europe and strengthen it with innovations in this
area. While primarily American companies dominate the
areas of extrusion processes and filament printing, the
metal systems necessary for industrial production in the
automotive and aerospace sectors are mainly dominat-
ed by German system manufacturers such as EOS, SLM
Solutions and Trumpf. The takeover of Swedish system
manufacturer Arcam and the German technology platform
Laser Concept by American engine manufacturer GE
Aviation in 2016 shows what a high importance additive
manufacturing has gained for the USA.
But the Western world is not alone in striving for a greater
use of additive manufacturing processes: Asian countries
are also positioning themselves with the provision of
financial backing. In China and Singapore, three-figure
million amounts have been set aside to prepare the local
industry for the transformation process into the age of
the Internet of Things. China is already conjecturing a
turnover of 1.12 billion US dollars gained in 2016 in the
3D printer and additive manufacturing market. The China
Industry Information Institute has forecast an amount of
7.68 billion US dollars for the Chinese AM market in the
year 2020, which would correspond to around a third of
the global overall market.
The generative manufacturing market is still manageable.
It is seen as fact for a few application areas and industry
sectors that there will be a transformation process to involve
a stronger use of additive manufacturing technologies.
The speed of the transformation process is influenced
by numerous factors. Above all, the often necessary ex-
pense of post-treating components produced in additive
manufacturing processes makes even more development
efforts necessary. But more and more system manufac-
turers are designing the processes and their material
logistics for mass production. The products and areas
of application most suited for additive manufacture are
currently the subject of intensive discussions. Whether we
will in retrospect attribute the character of an industrial
revolution to the change remains to be seen. The market
developments over the last five years, however, allow us
to suspect a large potential, above all for German and
Hessian companies. For this reason, the following chapters
will describe in more detail the essential technological
boundary conditions of additive manufacturing processes
and their potential for the various industrial sectors.
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 2.  ADDITIVE TECHNOLOGIES AND
MANUFACTURING PROCESSES
In the science-fiction saga Star Trek, the ‘replicator’ is
a system which can make components and weapons,
food and drink out of individual atoms, in a seemingly
arbitrary manner. Marshall Burns named his idea of the
digital home factory in 1987 ‘Fabber’ – a small decentral-
ised manufacturing unit which was meant to make the
vision of the production of individual parts into reality.
Since then, over 20 years have gone by and the further
development of production technology, software and
materials have made the future scenario ever more real-
istic (Peters 2011). The foundation for the development
8
is formed by so-called additive manufacturing principles
which, unlike conventional production processes, do not
remove material (as with turning, drilling, sawing, milling)
or reshape materials (as with bending, drawing); rather,
this approach generates the structures respectively. Thus,
the term additive (sometimes generative) manufacturing
has established itself in the specialist literature. Due to
the highly increasing use and commercialisation into the
consumer area, the name ‘3D printing’ has now become
the blanket term for the various process principles.
2.1 FUNDAMENTAL PRINCIPLES AND PROCEDURES

The additive manufacturing processes and system types
common today can be subdivided into five additive manu-
facturing principles according to the materials used. Here,
we assume different semi-finished products with various
starting materials and operating principles which effect
the layered structure of the components. In this way, the
variety of systems used today can be subdivided into
the process groups stereolithography, laser sintering/
laser melting, binder jet printing, fused layer modelling
or layer laminate manufacturing.
A selection of the individual technologies is generally
based on the materials which can be used, the precision
which can be achieved, the potential mechanical quality,
the maximum system construction space, along with the
cost framework. Given the current market dynamics, the
conditions are in a constant state of flux.

Classification of additive manufacturing procedures

Solid Liquid

Wire Powder Film / sheet Liquid bath

PHYSICAL BASIC PRINCIPLE / TECHNOLOGY

Melting and Melting and Bonding Cutting and Photo-

hardening hardening via binder joining polymerisation

Material extrusion Powder-bed-based Binder jet printing Sheet / film Material

bonding lamination printing

AM PROCEDURE

Fused layer Laser Laser beam Binder jet Layer Stereo-

modelling sintering melting printing laminating lithography

Plastic Plastic, Metal Gypsum, sand, Paper, Resin /

metal alloy ceramic alloy starch, plastic, PVC film, thermosetting
metal wood plastic

Division according to Dr. Ing. R. Anderl (Qualified Doctor of Engineering), Technische Universität Darmstadt, September 2017

9

Laser
2.1.1 Stereolithography (SL)
Stereolithography (SL) was developed at the University
of Texas in Austin at the beginning of the 1980s and is
regarded as the oldest additive manufacturing process.
At the end of 1987, 3D-Systems Inc. presented the first
system and has marketed it ever since. Stereolithography
was registered by Chuck Hall for patent as early as 1984.
Stereolithography currently achieves the greatest possible
precision. As a result, it is the most important technique
for creating master forms for fine casting, polyamide and
vacuum casting. FormLabs launched the first SL desktop
system on the market in 2012.
The process
Stereolithography creates component geometries based
on 3D CAD data by means of locally hardening (curing)
a light-sensitive photopolymer with the help of a laser
beam. Photopolymer resin is first filled into a resin bath
and the component platform is submerged below the
surface to a depth equal to the thickness of one layer
(usually between 50 and 100 microns). Exposing the
lines or layers of the shaped part geometry to the laser
hardens the photopolymer. This creates the first layer
of the desired component. The component platform is
progressively lowered in steps equal to the thickness of
one layer. The resin flows onto the platform from the side
and a blade distributes the resin equally across the already
hardened structure before the next layer is exposed to
the laser. The process is repeated until the shaped part
has been completed and the desired component height
has been reached. For a few new systems, the compo-
nent does not move downwards with the construction
platform during the process, but moves slowly upwards
out of the resin bath.
Thin supporting structures are required to prevent the
subsidence of the overhanging layers in the resin bath
and to stabilise the geometry. These have to be detached
from the component platform after removing the com-
ponent. The stereolithography components must then
be stored under UV light in order to completely harden
the material. As an alternative to the laser, some systems
utilise UV lamps and a screen. The screen only allows the
UV light to penetrate at the points where the resin should
be cured. This eliminates the complex mirror unit required
to control the laser beam.
10
1 Wiper distributes polymer
2 Laser passes over the surface
3 Construction platform lowers
4 Polymer hardened by laser
Mirror
2 Wiper 1
4 Workpiece
Construction platform
3 Resin container
(Liquid polymer)
The stereolithography process
Materials
Stereolithography systems can only process liquid pho-
topolymers such as epoxy resin or acrylic resin (vinyl-based
polymers even less so). After hardening, these materials
possess sufficient stability and temperature resistance
between 50-60 degrees Celsius. In the meantime, the
different resin systems are available on the market with
transparent, opaque, flexible, bendable, thermal stability
and biocompatible properties.
A large disadvantage of the process technology is that
the classic approach, including resin bath, does not allow
different materials to be used during a single working
process. Resin systems in liquid form also have a significant
environmental impact and, moreover, have a limited shelf
life. The further development of the resin mainly focuses
on improving thermal stability.
Component sizes, precision, reworking
Stereolithography can achieve the highest precision
among additive manufacturing processes. This is primarily
due to the thin layers with a detailed resolution of 0.01
to 0.02 millimetres. Today’s components have very good
surface qualities, they are smooth and the layer structure
is imperceptible. Standard systems have a construction
space with dimensions between 250 x 250 x 250 millimetres
(LxWxH) and 1000 x 800 x 500 millimetres. When it comes
to a construction space of 2100 x 700 x 800 millimetres,
the manufacturers refer to a mammoth stereolithography
system. Larger components can be assembled from
multiple smaller components. Subsequent surface treat-
ment using varnishing, coating or metallising is common.
However, the semi-transparency of the material is lost as
a result. The surface quality can be further enhanced by
polishing or material cutting.
Samsonite S’cure prototype in the Mammoth stereolithography system (Source: Materialise)
Application
Stereolithography is highly important for model construc-
tion as a means of manufacturing demonstration objects.
Thanks to their very high quality, the components are
also suitable for use as functional prototypes or master
models for fine casting and vacuum casting. However,
stereolithography components generally cannot be used
directly due to their low thermal stability. Process variants
can now also be utilised to generate nanostructures
and microstructures. Biocompatible resin systems are
being used more and more in dentistry and biomedical
technology.
Cost-effectiveness
By virtue of its history, stereolithography is the most
frequently used additive manufacturing technology. The
prices for common stereolithography systems have fallen
in recent years. Nevertheless, they still exceed 50,000 eu-
ros. As a result, a number of service providers have been
established. Since 2012, desktop systems and kits with
lower precision have been available from 4,000 euros.
However, the material is four times as expensive as the
material used in extrusion systems such as FLM (fused
layer modelling; see chapter 2.1.3). Furthermore, as the
excess material remains in the construction space after the
manufacturing process, a material consumption higher
than the actual component volume has to be included
in the cost calculations.
Special processes and system types
PolyJet Modelling (PJM))
Polyjet technology (also known as Multi Jet Modelling
MJM) can be compared to inkjet printing. A printhead
applies layers of liquid photopolymer to the component
platform. These layers are then immediately hardened
using UV light. In this case, the resin bath is not required.
However, supporting structures also need to be printed
to generate protruding elements. Polyjet modelling
achieves very high levels of precision of 16 microns for
the Z axis and 42 microns for X and Y axes. Furthermore,
it is the only system technology capable of utilising three
different materials in one process to create multi-material
applications (for example, hard-soft compounds).
Digital Light Processing (DLP)
Digital light processing is another variant of the stereoli-
thography process and works with UV light to harden the
photopolymer layer by layer. The light first hits the surface
of a microchip into which numerous movable micro-mirrors
are integrated. The beams of light are then reflected onto
the areas of the construction space to be hardened, and
serve to successively generate the component structure.
DLP systems are very compact, comparatively affordable
and are the preferred system in jewellery manufacture or
biomedical technology, for example.
Micro-Stereolithography (MSL)
Weighing only 1.5 kilograms and with the dimensions
of a milk carton, the world’s smallest stereolithography
printer was developed by Professor Jürgen Stampfl and
his team at the Technical University of Vienna in 2013.
It works with liquid resin, which is selectively hardened
through the use of LED light. The layers have a thickness
of 0.05 millimetres. The technology is regarded as having
major potential for future applications, which is why other
research institutions are also working on micro-stereoli-
thography.
11
 The exposure process when 3D printing high-performance
ceramics in the LCM process (Source: Lithoz)

Continuous Liquid Interface Production (CLIP)

In the spring of 2015, a new additive printing technology

Lithography-based Ceramic Manufacturing (LCM)
The LCM process for additive manufacturing of high-perfor-
mance ceramics was developed at the Technical University
of Vienna between 2006 and 2010 and has been mar-
keted by Lithoz GmbH since 2011 as a spin-off company.
It is based on exposing a photo-sensitive resin contain-
ing ceramic particles. The layers of resin are hardened
progressively to form a plastic-ceramic blank with the
photopolymer as a bonding agent between the ceramic
particles. The bonding material is then removed through
pyrolysis and the ceramic particles are thermally sintered
and permanently melted together. During de-bonding, a
degree of shrinkage must be taken into account. Subse-
quently, the components have a density of 99.4 percent.
was introduced in the USA based on photopolymerisation,
which is supposed to be 25 to 100 times faster than the
conventional process and leaves behind no visible layer
structures. The additive process takes place in a resin vat,
the base of which consists of a light- and oxygen-perme-
able membrane. An ultraviolet beam of light illuminates
the desired cross-section of the object from underneath
through the base of the bath onto a platform which is
slowly but continually pulled upwards out of the resin
bath. The introduction of oxygen prevents hardening of
the entire surface of the construction space. A specially
developed software controls the whole process.

Silicon printing

In 2016, chemistry company Wacker first introduced a

technology for the layered construction of components
from silicon elastomers. This had not been possible
before due to the high viscosity of the material. With
the so-called Drop-on-Demand-Jetting, the material is
applied to a construction platform from a printhead drop
by drop and then cured under UV light. Layer by layer,
homogeneous part geometries with smooth surfaces
arise which have technical qualities comparable to those
of standard injection-moulded silicon parts. This process
achieves 85-90 percent of the stability generated by the
conventional process. Hollow spaces and overlays can
be achieved with water-soluble supporting materials.

Futurecraft 4D – a sole for a sports shoe manufactured

additively in the CLIP process (Source: Adidas)

Gel Dispensing Printing (GDP)

GDP is a gel-based process which was developed by

an Israeli systems builder to create particularly large
plastic components. Using an extruder, a highly viscous
acrylate-based gel is applied in layers and hardened by
way of UV light. The light source is located directly on the
printhead. The system has a construction space of 1.17
x 1.5 x 1.8 metres and achieves a construction speed of
0.33 metres per hour along the Z axis with a throughput
of up to 2 kilograms per hour.

12 ACEO 3D-Silikondruck (Quelle: Wacker)

2.1.2 Selective Laser Sintering

Thanks to its ability to achieve qualities similar to the ones

of series material, selective laser sintering (SLS) is one of
the most important powder-bed processes for industrial
applications. It was developed in the mid-1980s at the
University of Texas by Joe Beaman and Carl Deckard.
Laser sintering works with powdered starting materials
which are melted using a laser. It has long been used for
mainly prototype and tool construction. In the present
day, it is also one of the most important additive manu-
facturing processes for direct component manufacture
(Direct Digital Manufacturing). At the beginning of 2014,
a number of key patents for selective laser sintering ex-
pired. This means that we can expect a decrease in the
consistently high prices for components and systems
over the next few years.
The term selective laser melting (SLM) is now utilised when
referring to processing metal powders. As a result of the
use of multiple lasers in one system, a productivity increase
of 100-fold up to 1,000-fold is expected in the coming
years. With the powder-based Multi-Jet Fusion large-scale
system, PC printer manufacturer Hewlett Packard entered
the 3D product printing market in 2016. GE Additive also
introduced an SLM large-scale system under the name
of A.T.L.A.S. at formnext 2017, the international additive
manufacturing trade fair. In 2016, the first desktop SLS
systems appeared on the market for a purchase price of
5,000 to 10,000 euro.
Mirror
Laser
The laser sintering process (Source: EOS)
The process
Selective laser sintering is based on the local sintering and
melting of powdered materials through the heat generated
by a laser beam, utilising 3D CAD data. A roller-shaped
coating unit applies a thin, even layer of powder to the
printing bed and smooths it. Exposing layers or lines of
the corresponding areas results in the melting of the
powdered material, which by subsequently cooling and
hardening creates a shaped partlayer. Once the exposure
of a component layer has been completed, the printing
bed moves one layer downwards and material powder
is applied again (material thickness between 0.001 and
0.2 millimetres) and the sintering process is repeated for
the next layer structure. Because the solidified material
composite is surrounded by loose powder, a supporting
structure is not required to construct protruding elements.
However, additional structures are required to hold the
component in position when working with high-energy
lasers. The entire printing area in most systems is heated
to a temperature below the melting point of the powdered
material used to reduce the process time. The entire
printing area has to be cooled evenly over a period of
several hours before removing the finished component
from the powder bed. Unused powder can be reused.

2
Roller
1

4 Workpiece 1 Roller distributes polymer

Construction 2 Laser passes over the surface
platform
3 3 Construction platform lowers
Powder
4 Powder hardened by laser

Powder store or powder collecting vessel

The selective laser sintering process

13
 Materials

In principle, any material which can be melted and man-

ufactured as a powder is suitable for use with selective
laser sintering. Numerous plastics (for example PA 22, PA
12, PS, PEEK, thermoplastic elastomers), ceramics, metal
alloys (tool steel and stainless steel, aluminium, titanium,
cobalt-chrome, bronze, precious metals, nickel-based
alloys) and quartz sand are commercially available. The
powders are generally manufactured synthetically be-
cause of the need for an even grain size. When handling
powdered materials with grain sizes between 20 and 100
microns, the existing legal regulations regarding work
safety apply. Furthermore, experts such as representa-
tives from the Federal Institute for Occupational Safety
and Health (BAuA) strictly advise caution when handling
the powder as the ultrafine particles can enter the human
lung. As such, wearing a mask is recommended. When
processing metallic powder, a protective gas such as ni-
trogen or argon is normally used inside the compartment
to prevent oxidation.
Researchers at the Fraunhofer Institute for Laser Technolo-
gy (ILT) in Aachen have succeeded in additively manufac-
turing components consisting of different copper alloys
with a density of 99.9 percent by integrating a 1,000 watt
laser system into an existing SLM system. The process also
allows objects to be manufactured out of high-strength
zirconium oxide ceramic and aluminium oxide ceramic.
The market dynamics mean that the range of printable
powdered metal alloys is constantly expanding. For exam-
ple, Heraeus has specialised in the provision of stainless
steel powder for electron beam melting (EBM) and laser
beam melting (LBM). Platinum group metals (PGM), gold
and silver alloys, refractory metals, amorphous metals,
titanium, titanium aluminides and customer-specific alloys
are offered. Special developments such as inter-metal
alloys, bioresorbable materials, gradient materials and
amorphous metals (metallic glasses) are also available.
The manufacturer makes the optimal processing param-
eters available for each metal powder in the context of
the additive manufacturing process.
Removing the component from the powder bed
(Source: Evonik Industries)
Component size, precision, reworking
The construction spaces of laser sintering systems are
currently between 150 x 200 x 150 millimetres and 1100 x
1100 x 450 millimetres. Some large systems work with up
to four lasers to shorten processing time. The construction
rate for metal systems is currently between 2 and 100 cubic
centimetres per hour. Systems with up to eight lasers are
currently in development. Laser-sintered components
have rough surfaces as a result of the grain sizes of the
powder. As a rule, the components have a precision of
+/- 0.1 millimetres, while values of +/- 0.02 millimetres
have now been achieved for metal components. The
layer thicknesses can vary between 1 and 200 microns.
The usual layer thickness for metals such as stainless steel
and tool steel is 20 microns or 40 microns, in the case
of aluminium, it ranges from30 to 50 microns. Whereas
creating highly dense metal components required infil-
tration with low-melting metals up until a few years ago,
laser beam melting (LBM) now generates highly dense
components (> 99.5 percent) with very good mechani-
cal characteristics. In fact, the material strength actually
exceeds that of commercially produced components in
some cases. Depending on the component geometry,
significant warpage must be factored in as a result of the
thermal influence of the laser, in particular for the LBM of
metal parts. The rough surfaces can then be smoothed
to a glossy finish using ablative processes such as mill-
ing. Before starting a new LBM process, the component
platform must generally be face milled.

14

Laser-sintered handles of the Nikon Metrology Scanner with
flocking (Source: Materialise)
Application
Up until a few years ago, SLS or SLM components were
primarily utilised as functional prototypes. Today, laser
sintering or laser melting can also be employed to directly
manufacture customised components and small series. The
typical areas of application include biomedical technology
(such as tooth inlays, implants, hearing aids), tool and
die manufacturing (alloy die casting and fine casting, for
example) along with mechanical engineering, aerospace
and the manufacture of replacement parts in vehicle
construction. Laser sintering has also been utilised in the
design and jewellery industry for approximately a decade.
GE Aviation has set up a site with additive production
facilities in Alabama where laser sintering systems are
used to manufacture components for aircraft engines. In
2016, the company took over the two European system
manufacturers Arcam and Laser Concept.
SLS extension cable ‘Double Helix CABLE’ (Source: CIRP, Design : Yusuke Goto)
Cost-effectiveness
Because of the high system costs (average price of an
industrial system: 80,000 US dollars; Horsch, Florian:
3D-Druck für alle – Der Do-it-yourself-Guide. Munich,
Vienna: Carl Hanser Verlag, 2014) the use of laser sinter-
ing must be carefully calculated. In a single work stage,
several component geometries are usually manufactured
at the same time and the construction platform is densely
packed to make operating the system financially viable.
The costs for laser-sintered components range from a
few hundred to several thousand euros, depending on
the material used. As a result, the costs are higher than
those of other processes, which still tends to make its use
in a small-company context impracticable. With increas-
ing rates of construction, the costs will sink in the future.
Service providers are widely spread.
Special processes and system types
Electron beam melting (EBM)
In one process variant an electron beam is used instead
of a laser to achieve a higher power output (3 – 10 kilo-
watt in comparison to 250-1,000 watt for SLS/SLM). This
allows even high-strength steels to be manufactured with
a shorter processing duration. Electron beam melting
enables the direct manufacturing of metallic components.
For this reason, the Swedish systems manufacturer Arcam
AB markets its EBM systems under the brand name of
‘CAD-to-Metal’.
15

Desktop SLS system (Source: Sintratec)
Desktop SLS
After key patents for selective laser sintering expired,
new system manufacturers appeared in the market. Here,
among other things, the market focus is on small and
affordable desktop solutions. One of the first mini-laser
sinter systems was introduced in 2015 and comes from
Polish start-up “SinterIT” from Cracow. The system has
dimensions of 66 x 62 x 40 centimetres, weighs only 40
kilograms and has a maximum construction space of 150 x
200 x 150 millimetres. With a laser diode output of 5 watt,
layer thicknesses between 0.075 millimetres and 0.175
millimetres can be achieved. With the black polyamide
powder (PA12), the companies are offering a material with
which rubbery, flexible components can be implemented.
Further suppliers of affordable SLS systems are Swiss
company Sintratec and Italian manufacturer Sharebot.
HP Multi Jet Fusion
The powder bed technology from Hewlett Packard is a
large-scale system (construction space: 406 x 406 x 305
millimetres) for additive product printing which was pre-
sented in 2016. It works with an infra-red energy source
rather than with a laser. The plastic powder is applied
in layers, using an inkjet printhead, two bonding liquids
with different thermal conductivity are incorporated. One
is particularly thermally conductive and strengthens the
melting effect of the particles in the areas of the desired
component. The other liquid is applied to the edges of the
part geometry and acts as a thermal blocking layer. The
result is sharp edges, smooth surfaces and a clean print
result. Layer thicknesses of 70-80 microns are possible.
The system is first optimised for the use of a fine-grained
PA 12 powder from Evonik. With a print speed of 4,500
cubic centimetres per hour and a possible resolution of
1,200 dpi, the system is a competitor of plastic injection
moulding in small-series production.
16
Multi-material laser beam melting
Until now, laser sintering processes could only process one
material. With a view to expanding additive production,
the generative manufacture of composite structures or
the combination of various material qualities in metallic
high-performance components would be very interesting.
For more than three years, scientists at the Fraunhofer
IGCV have been conducting research on the simultaneous
processing of two metal alloys in a construction process
using laser beam melting (LBM). In summer 2017, the first
3D printed multi-material component was presented. The
success is the result of a new kind of application method
of an LBM system which was integrated on a software and
hardware basis. Here, a 3D multi-material component
could be produced from tool steel 1.2709 and a cop-
per-chrome-zirconium alloy (CCZ) in an additive manner.
Laser powder coat welding
Laser coat welding (LMD) is a process which has been
established for years for the application of thick metallic
layers as a wear-resistant coating or to repair a compo-
nent. It is not a laser sintering process, however, it is used
today in the context of metallic 3D product printing. Here,
metal powder is blown into a laser beam. The high energy
output of the laser beam melts the powder and binds it
metallurgically into a permanent layer. On the basis of
3D-CAD data, 3D metal structures can be created. The
component size is not limited when using the laser powder
coat welding process. The smallest structural resolution
is 30 microns. Steel, titanium, aluminium, nickel and
cobalt alloys can be processed. Inter-metallic titanium
aluminides and nickel-based high-temperature materials
are currently in development.

2.1.3 Fused Layer Modelling
As a result of the expiry of a number of important industrial
property rights in 2009, there has been a development
boost for so-called fused layer modelling processes.
Systems following this process approach are now among
the most important additive manufacturing techniques
for use in creative professions and private contexts. This
is due to the less complex design of the systems, the easy
handling and the broad range of available materials. The
good mechanical qualities also play a role. Because the
systems generally work with fusible filament materials,
the terms fused filament fabrication (FFF) and fused layer
modelling (FLM) have become prevalent. The commonly
used term fused deposition modelling (FDM) is a trade-
mark of the American company Stratasys Ltd. Besides the
filament printers, so called fused granular fabrication (FGF)
printers using granulate have also been established on
the market. These allow for quick 3D printing of particu-
larly large components. Cincinnati Inc. (USA) operates a
BAAM system (Big Area Additive Manufacturing) with a
construction space of 6 x 2.3 x 1.8 metres.
The extrusion process in operation
(Source: Delta Tower, Thorsten Franck)
1 Supporting and construction material
is drawn into the printhead
2 Extrusion head heats the supporting
and construction material
3 Construction platform lowers
1
4 Construction and
supporting material
is applied
2
Extrusion nozzles
Extrusion
head
Workpiece
4
Supporting material
Construction
platform
3
Roll Roll
construction
material
supporting
material
The extrusion process
The process
Fused layer modelling processes work with a material
which softens when heated. Similar to a hot glue gun,
the material is pressed through a heated nozzle and ap-
plied either in lines (for example FLM) or in droplets (for
example freeformer). A control mechanism regulates the
distribution of the layers of the material on the component
platform or on the existing structure, where the material
then cools and hardens immediately. The component
is manufactured successively by fusing the individual
layers. The print bed is lowered a fraction of a millimetre
after every layer. The layer thickness is determined by
smoothing with the nozzle. Common layer thicknesses are
between 0.025 and 1 millimetre. Undercuts and hollow
spaces are only possible to a limited degree with this
process. As such, fine supporting structures are required
to manufacture steep component geometries. On new
system types, the supporting material is simultaneously
supplied from a second coil and applied. The supporting
construction has to be removed after printing. The use
of a water-soluble or an alkaline-soluble thermoplastic
is helpful for this.
Materials
Lange Jahre waren die für das Fused Layer Modeling For
many years, the materials which could be utilised for fused
layer modelling were restricted to a few thermoplastic
materials such as ABS, polyester or polycarbonate, or
various types of wax. With the invention of bioplastics, PLA
became the new standard material. Due to the widespread
use of filament printers in creative professions, the market
reacted with new materials and composites to meet the
demand for more versatile design options. Filaments are
now available which are capable of generating wood-like
(such as LAY-Wood), ceramic (such as LAY-Ceramic) or
17
 sandstone-like surfaces (such as LAY-Brick) or which have
electrically conductive, magnetic or visual properties. Fila-
ment solutions for the implementation of 3D membranes
and porous filters or bendable, rubber-like objects are
also available on the market. The BioFabNet project has
been developing organic-based materials solutions, for
printers in the consumer sector in particular, since the
end of 2013. Several scientists and designers have also
been focusing on the development of filament solutions
based on waste materials and recycled goods. In autumn
2014, American Mark Forged from Boston presented
the world’s first carbon fibre filament printer. In 2017,
several manufacturers of metal filament also joined in to
make it possible to manufacture metal components in an
affordable manner by using filament printers.
Lay-Wood wooden filament (Source: ccproducts)
Component size, precision, reworking
The sizes of the systems available on the market range
from just a few square centimetres to more than a square
metre. Generally, the process technology is not limited
to one construction space as the nozzle with the filament
could also be moved with a robotic arm. Reworking is a
complex process, given that thermoplastics are generally
used. ABS surfaces, for example, can be vaporised, edged
and smoothed with acetone. Imprecision along the Z
axis must be factored in because of the nozzle diameter,
in particular with small components. Due to different
solidification rates within the printed part, warpage has
a negative impact on the quality of the component.
Additionally, individual layers may become de-bonded.
18
Application
Although additive extrusion systems were primarily used
for manufacturing demonstration models, they are now
seeing more widespread use in direct product manu-
facturing and in private applications. More and more
companies are entering the market for systems suitable
for office use. Applications for the furniture industry and
interior design are currently being tested as a result of the
development of higher quality materials. DIY shops have
also expanded their range of 3D printers and services to
include options for the creative DIY fan.
Cost-effectiveness
The prices for filament-based printers have decreased
significantly since it has become possible to purchase
construction kits on the internet. They can now be pur-
chased from trade dealers at prices between 500 and
800 euros. Construction kits are available for less than
200 euros. However, the low-cost systems do not deliver
high precision. Higher quality systems in the consumer
sector are available at prices between 1,500 and 3,000
euros and industrial systems at a price no less than 10,000
euros. The filaments are offered for 10 to 50 euros per
kilogram in various colours.
Special processes and system types
BIG Fused Granular Fabrication (FGF)
The start-up, BLB Industries from Värnamo in Sweden
presented the first European FGF large-scale printer
in 2016. This can process standard granulate and ad-
ditively produce plastic parts in a construction space
with the dimensions of 1.5 x 1.1 x 1.5 metres and with a
throughput of 6 kilograms per hour. The system is based
on the platform concept and can be adjusted according
to size. The developers state that the maximum size is 5
x 5 x 5 metres and the maximum production capacity 35
kilograms per hour.
Freeformer
The die casting systems manufacturer Arburg entered
the additive manufacturing market at the end of 2013
with the freeformer. As such, the mechanical engineering
company was the first manufacturer to use commercially
available material in the form of standard granulate. This
is melted in a heated plastifying cylinder and applied in
the form of plastic droplets. The patented nozzle cap
utilises high-frequency piezo technology which enables
rapid opening and closing for up to 200 plastic droplets
per second and a precise material application. Using the
series material generates components which have 70 to
80 percent of the strength of comparable die-cast parts.
The freeformer has a construction space of 230 x 135 x
250 millimetres. Components featuring different plastics
(for example hard-soft-compounds) can also be created
with the use of a second nozzle.

High-performance PEEK plastic filament

The start-up Apium Additive Technologies from Karlsruhe

is the first company to make it possible to use filament
printing for high-performance polymers such as PEEK
(polyether ether ketone) for industrial applications with
its system. This was not possible before because of the
special material qualities. As well as the PEEK filament with
its printing system, Apium also offers a filament solution
with carbon fibres. This means that filament printing can
also be applied in mechanical engineering and biomedical
technology for high-strength components.
Fibre-reinforced 3D printing (Source: Mark Forged)
Composite 3D printing
The American company Markforged presented the
world’s first FLM system at the end of 2014, with which
fibre-reinforced components can be produced. The
system works with carbon fibre as well as with fibreglass
reinforcement and has a maximum construction space of
320 x 154 x 132 millimetres. The standard version costs
6,500 euros. According to developer information, the
carbon fibre-reinforced components are 40 percent more
stable than comparable components made from ABS. In
addition, they are supposed to have a significantly better
stability-to-weight ratio than those made from 6061-T6
aluminium.

3D printed implant made of PEEK

(Source: Apium Additive Technologies)

19

A component printed with a metal filament
(Source: Fraunhofer IFAM Dresden)
Metal filament
The XERION group, in collaboration with the Fraunhofer
IFAM in Dresden, is currently developing a process to be
able to produce metal parts with filament printing. The
plastic-based printing filament is enriched with metal pow-
ders; after printing, the excess plastic parts are expelled
using heat. Subsequently sintering the so-called “green
compact” at a high temperature solidifies the component
and retains the component thickness typical of metal, as
well as the stability. Here, a significant degree of shrink-
age must be taken into account. The special feature of
the plan is placing the printer, the oven system and a
mechanical mill in one single unit. All three systems will
have the same controls, including recipe management.
20
Effect when printing with retroreflective filament
(Source: Kai Parthy)
Reflect-o-Lay
The printing filament developed by cc-Products contains
millions of the smallest reflective pigments. This allows for
the visual effect of retroreflection, which we see in high-
viz traffic clothing, for example, to be transferred to 3D
printed objects. Under normal conditions, the material
appears in its typical grey colour. But if you shine a light
onto it, the rays of light are always reflected back in the
precise direction they come from.
3D printing filaments from locally produced algae
Over the last six years, the two Dutch designers, Eric
Klarenbeek and Maartje Dros, have developed a biocom-
patible material suitable for 3D printing based on algae.
In the production process, the algae are first cultivated,
dried and transformed into a printable filament with other
natural and locally available additives and a biopolymer.
The driving force behind this development was not just
being able to offer an alternative to classic plastic filaments.
Rather, the carbon footprint was the guiding principle,
as algae absorb CO2 from the atmosphere as they grow.
3D printed containers from an algae-based printing filament
(Source: Eric Klarenbeek and Maartje Dros)
Graphene-based FLM printing
Trend researchers at Frost & Sullivan are expecting 3D
printing with filaments to be the next development leap in
the additive manufacturing market. Graphene is a stable
modification of carbon with a two-dimensional structure,
where carbon atoms are structured in a way similar to a
honeycomb. It has a high degree of rigidity and is suit-
able as an electrical conductor. Graphene filaments are
expected to have application potential in electronics and
printable battery systems.
Laser wire coat welding
An alternative system to laser powder coat welding
works with a conventional welding wire. Compared to
powder-based coat welding, working with welding wire
offers advantages in terms of the process design, mate-
rial utilisation, the quality of the surfaces and the simple
procurement of starting material. The smallest possible
structure resolution is currently 600 microns. Here, in prin-
ciple, all welding additives available in wire form can be
processed. In summer 2017, Berlin-based Gefertec GmbH
presented a large-scale system for wire coat welding to
the market. With triple-axis processing, metal components
with a volume of up to 3 cubic metres and a maximum
mass of 3000 kilograms can be produced additively.
Large-scale system for additive wire coat welding
(Source: Gefertec GmbH, Berlin)
21
 2.1.4 Binder jet printing
Binder jetting (historically called 3D printing) was de-
veloped at the start of the 1990s by Emanuel Sachs and
Michael Cima at the Massachusetts Institute of Technology
(MIT) in the USA with the aim of providing a technology
for use in office environments. Based on the cost struc-
ture for these areas of application, filament printers are
probably more relevant here today. Due to the possibility
of adding colour to the printed components, binder
jetting processes have been used for a vast number of
application options by private users, for example, when
producing images of people.
ColourJet printing – 3D printing system (Source: Materialise)
The process
The process is similar to laser sintering and is based
on bonding particles with each other. However, unlike
selective laser sintering, these particles are not melted
with a laser, but rather bonded locally through the use of
a binding agent. The system utilises a printhead which is
managed by a control unit and moves in layers over the
powder bed. It applies droplets of the adhesive substance
to the newly applied layer of powder. The binding agent
penetrates the layer below and binds the new layer of
powder with the existing printed geometry. Before start-
ing to generate the next layer, the print bed is lowered
by the thickness of one layer and the process begins
again. As the component is completely surrounded by
powder during the manufacturing process, supporting
structures are not required for protruding elements, just
as during laser sintering. The printed components can
be infiltrated with resin or wax in order to increase their
mechanical strength.
22
1 Roller distributes powder
2 Binding agent is applied by the printheads
3 Construction platform lowers
4 Powder bonded via binding agent
5 Printheads for the
colours black, clear,
Roller Printheads
2
cyan, magenta, yellow
1
4 Workpiece
Construction
platform
3 Powder
Powder storage or powder collection container
3D printing process with a binding agent
As binder jetting is similar to conventional 2D printing,
the technology has proven itself quickly. In comparison
to other additive processes, binder jetting is capable of
achieving very high speeds. In addition, the components
can also be coloured with more than 16 million colours.
Unused powder in the construction space can be reused.
Materials
Materials based on starch, gypsum or sand and ceramic
composites are the standard materials utilised for binder
jetting. A number of systems manufacturers also supply
powders made of various metals for use in dental medicine
or offer mixtures for industrial applications and casting
moulds. When working with ceramic or metal powders,
the object undergoes a sintering process in a furnace
after printing. The subsequent infiltration with low melt
metals fills the pores and increases the density to up to 95
percent. In order to improve the quality, the process for
metal powder in layer thicknesses of just 25-100 microns
could be optimised. It is possible to attain particularly
high stability with hot isostatic pressing.
 Component size, precision, reworking
Thanks to the mature inkjet printhead technology, binder
jetting is one of the fastest additive processes. Systems
with a construction space of up to 4 x 2 x 1 meters are now
available (systems manufacturer: voxeljet). A precision
of 600 dpi can be achieved. However, the components
always have a rough surface with visible printing lines
due to the grain size of the powder used. These can be
reduced through mechanical reworking. For this reason,
current research is focusing on improving the mechan-
ical qualities of the printed components. As a result of
work carried out at the Fraunhofer Institute for Structural
Durability and System Reliability (LBF) in Darmstadt, new
material systems and printable inks have been improved
to the extent that three-dimensional printing is capable
of achieving similar mechanical strengths to die casting.
Application
Until recently, most small systems capable of tinting with
more than 16 million colours were primarily utilised for
rapid visualisation during the drafting process. The quiet
production process and closed system structure make
the process suitable for use in office environments. With
large office spaces, binder jet printers are now becoming
more widespread in industrial fields of application, for
example in the manufacture of sand grains for foundries.
The printers can also be used for series production. Sand
printing has already been used to manufacture architec-
tonic structures. Metal and ceramic shapes produced using
binder jet printing and subsequently sintered are used in
industrial mould construction, for example.
S-Max large-scale system for industrial binder jetting
(Source: ExOne)
Cost-effectiveness
The system prices range from between just under 20,000
euros to prices in the six digit range. Therefore, usage in
a personal or small-business environment is largely ruled
out. As a result, there are numerous service providers
active on the market who are able to create components
at realistic prices.
Special processes and system types
S-Max – Industrial 3D production printer for sand and
metal
ExOne is one of the most prominent providers of binder
jetting printers with large construction spaces for shaped
parts made from sand or metals. The S-Max offers a robust
and reliable solution for all cold-setting binder systems
in sand printing. It is suitable for almost all cast materials.
Here, large and complex shapes and cores can be man-
ufactured even quicker and more reliably. Thanks to the
double job box and the large construction spaces, each
measuring1,800 x 1,000 x 700 millimetres, the S-Max
produces each prototype requirement as well as whole
series with efficiency and a high level of performance.
23

VX400 – The world’s largest industrial 3D printer
With a construction space of 4,000 x 2,000 x 1,000 mil-
limetres, with the VX4000, voxeljet is offering what is
currently the world’s largest 3D binder printing system
for sand shapes. As such large volumes have a very heavy
weight on the construction platform, the platform is not
lowered during the process; the printhead is raised layer
by layer instead. Using a rail system, the sand shapes are
extended and thus an economical production is made
possible. The resolution is 300 dpi, the layer thickness
300 microns.
Ceramic printing
Based on a voxeljet system, American company Boston
Ceramics has created a 3D printing process for manu-
facturing customisable wall tiles and ceramic decorative
objects. This process uses thermally stable and recyclable
material including binding agents which bond the pow-
der particles together into an object. The system has a
maximum construction space of 4,000 x 2,000 x 1,000
millimetres. Ceramic parts with highly detailed surface
features can be generated in a lot size of 1.
2.1.5 Layer Laminate Manufacturing
Layer laminate manufacturing (LLM) consists of systems
based on the use of individual films or paper layers. In
recent years, the systems have not developed as much as
other system types because it is difficult to create hollow
spaces and the excess material must be removed manu-
ally. The term laminated object manufacturing (LOM) is
also common and is a protected trademark of American
manufacturer Helisys Inc., who has been marketing the
first systems since the mid-1990s. When working with
paper, the term paper lamination technology (PLT) is
also currently used.
24
1 Endless belt with adhesive-coated material
2 Laser passes over the cut surface
3 Construction platform lowers
4 Material bonded with a hot roller
Laser
Mirror
2
Workpiece
Hot roller
1 4 1
Construction
platform
3
Rollers with adhesive-coated material
The layer laminate manufacturing process
The process
LLM systems manufacture components by bonding layers
of individual films or thin sheets with each other. First,
the initial layer is placed on the component platform and
the contour of the layer is shaped with a laser, a sharp
blade or a hot wire. The platform moves downward and
a new material film is moved into place and bonded to
the layer below using a thermal roller with a temperature
of around 300 degrees Celsius. The next contour cut is
made and the process is repeated from the beginning.
The excess film material is cut into small square pieces
in order to simplify removing the component at the end
of the process. The resulting cubes can be disposed of
easily. At the same time, the excess material also serves
to support protruding elements, eliminating the need for
any additional supporting structures. The process can be
stopped to integrate functional elements or to remove
excess material from the hollow spaces. Due to the nature
of the process, layer laminate manufacturing is regarded
as an additive process but demonstrates fewer advan-
tages, particularly with regard to saving resources, when
compared to other additive manufacturing processes.
Construction space of a MCor system after the layer lamination
process (Source: 3D-Picture, Photo: Dieter Bielert)
 Materials
A variety of different film materials and coated papers
are available on the market for layer laminate processes.
These range from a variety of different plastics (such as
polyester) to fibre-reinforced composite materials. Further-
more, ceramic and metal films have also been processed
successfully in trials. When working with metal materials,
the individual layers are not bonded but welded. Although
processing paper already creates an appearance which
resembles wood, a special system variant was developed
for generating wooden components. With this system, the
component platform is located at the top and the material
is milled with a cutter head. This arrangement makes it
easier to create hollow spaces because gravity causes the
excess chips to fall out of the construction space.
Component size, precision, reworking
The layers that can be processed with LLM systems range
from between 0.08 and 0.25 millimetres in thickness
with the most common thickness being 0.1 millimetres.
A number of manufacturers also specify the material
thickness of standard paper used with the conventional
grammage. In this case, 80 grams per square metre is
typical. LLM systems available on the market have a max-
imum construction space of 800 x 600 x 550 millimetres
with a precision of +/- 0.1 millimetres. The mechanical
strength of the components depends on the construction.
As such, the direction of lamination must be considered
when reworking. When using paper, the surfaces must
be sealed afterwards with clear varnish due to their hy-
groscopic properties. New systems dip the workpiece in
synthetic resin after the excess paper has been removed.
This gives the printed object a silky, shiny surface.
Application
Owing to the component-independent process speed, LLM
processes are particularly advantageous when creating
particularly large part geometries with limited complexity.
No tension occurs when bonding the layers and largely
distortion-free shaped components can be manufactured
as a result. They are frequently used for model construction
(such as for foundry models). Yet, these processes have
clear disadvantages when compared to other additive
processes because only limited hollow space contours
can be created. A paper-based layer laminate system for
office usage is now available on the market.
Cost-effectiveness
LLM systems are relatively cost intensive compared to
other types of systems and prices begin at 4,000 euros.
Moreover, the low-cost systems are also limited to specific
film materials.
Special processes and system types
MCor paper-based layer laminate system
The company MCor was founded in Ireland in 2005 and
manufactures layer laminate printers that work with con-
ventional A4 letter paper. As such, the operating costs
are significantly lower in comparison to other additive
manufacturing technologies. The layers of paper are
bonded to each other, the layer contours cut and then
tinted using conventional printing technology. Given that
more than one million colours are available, photo-realistic
objects can be created. The ink penetrates the individual
layers of paper and creates a saturated colour effect. The
colour resolution along the component axes is 5,760 x
1,440 x 508 dpi (x-y-z). A maximum component size of 256
x 169 x 150 millimetres can be constructed. A desktop
system for a maximum component size of 245 x 205 x 125
millimetres has been available on the market since 2016.
Plate press brazing
Neue Materialien Bayreuth GmbH developed a new
additive process under the name of plate press brazing
(PPB). It is based on a combination of milling and brazing
and offers the option of generating large-surface tool in-
serts with complex internal structures such as contoured
cooling ducts. Four-millimetre thick metal plates coated
with brass solder serve as the basic material. The layer
geometry is milled on the individual panel, the panels
are then stacked to form a perfect fit, and permanently
bonded with each other by means of contact soldering.
Uneven areas are removed by specifically applied pressure
via the closing device. The process is now so advanced
that a precision of 80 microns can be achieved.
25
 2.1.6 4D Printing and 4D Textiles
In 2013 at the Self Assembly Lab of the Massachusetts
Institute of Technology MIT, a research team led by Skylar
Tibbits first presented 4D printing technology. Here, the
scientists used printing material developed by American
systems manufacturer Statasys which changes it shape
under the influence of temperature, light, moisture or a
magnetic field and can trigger functions. The scientists
expect the new process technology to present applica-
tion options for self-building structures in space, piping
that can adjust according to the flow volume, automatic
windows or self-building furniture.
Research groups worldwide are now showing interest
in the new technology and testing which areas of ap-
plication 4D printing can have for a few of the largest
industry fields. As well as use in biomedical technology,
for example for implants or exoskeletal structures, there
are also application options primarily in architecture and
the textile and furniture industry. Shape-changing compo-
nents on wings or changeable body parts for vehicles are
currently being investigated in studies in the aerospace
and automotive industry. Due to the numerous research
plans and potentials, 4D printing was first incorporated
as one of the up-and-coming technologies in the Gartner
Hype Cycle in 2016.

Expectations
Connected Home
Deep Learning Plateau will be reached in:
Virtual Assistants
IoT Platform Machine Learning less than 2 years
Autonomous Vehicles
Smart Robots 2 to 5 years
Nanotube Electronics
Edge Computing Cognitive Computing
5 to 10 years
Augmented Data Blockchain more than 10 years
Discovery Commercial UAVs (Drones)
Smart Workspace
Conventional
Brain-Computer User Interfaces Cognitive Expert Advisors
Interface Volumentric
Quantum Displays
Computing
Digital Twin
Serverless PaaS
5G
Human Enterprise Taxonomy
Neuromorphic Augmentation
Hardware and Ontology
Deep Reinforcement Management
Virtual Reality
Learning
Artificial General Software-
4D Printing Intelligence Defined
Security
Augmented
Reality

Smart Dust
As of July 2017

Innovation Peak of Trough of Slope of Enlightenment Plateau of

Trigger Inflated Disillusionment Productivity
Expectations

Time

Gartner Hype Cycle for Emerging Technologies 2017 (Source: Gartner Inc., USA)

26
Wet and light-sensitive printing materials

The MIT collaborated with software company Autodesk

to develop various printing materials which can be used
for 4D printing. The first successful tests lead back to a This series of images shows the transformation of a 4D printed
hydrophilic acrylate monomer which hardens under UV hydrogel-composite structure after being dipped in water (Source:
light and forms a hydrogel with a volume enlargement A. Sydney Gladman, Elisabetta A. Matsumoto, L. Mahadevan,
Jennifer A. Lewis: Harvard University and the Wyss Institute for
of up to 50 percent when placed in water. Light-sensitive
Bioinspired Engineering, USA)
printing materials have already been tested successfully
for changing carbon fibre structures.

Hygroscopic wooden printing filament

David Correa followed a similar approach with a research

team from the University of Stuttgart. The printing tech-
nology was developed for a hygroscopic wooden filament
insofar as architectonic structures could be created which
react to fluctuations in environmental influences. In the
future, the scientists want to print window elements out of
wood which can close when it rains and open themselves
when it is sunny.

4D printing with hydrophilic acrylate monomer (Source: MIT, USA)

Hydrogel and cellulose fibrils

Scientists at Harvard University have succeeded in using

a printing ink made from a hydrogel and cellulose fibril to
reconstruct the natural movement of plant blossoms under
the influence of moisture. Cellulose is particularly highly
hygroscopic. Under the influence of moisture, it tends to
curl up more along the fibre direction than horizontally
to it. After the material was 3D printed in two directions,
the material composite began to incline and bend under
the influence of moisture. As well as the printing ink, an
algorithm was developed to predict the transformation.
The result was the reconstruction of natural functions
from the world of plants.

4D printing of a form-changing window structure

(Source: David Correa, ICD/University of Stuttgart)

27
 This object was printed as a flat structure (left) and can then
be reshaped into two stable and load-bearing shapes (middle Shape-memory alloy
and right) (Source: ETH Zurich, Tian Chen)
The Laser Zentrum Hannover (LZH) successfully produced
a cochlea implant for the deaf in 2014 by laser sintering a
powdered nickel-titanium alloy shape-memory material
which first moves into its final position within the ear under
Shape-memory polymer the influence of heat and optimally adjusts its geometry
according to the cochlea shape of the individual. Implants
At the Swiss Federal Institute of Technology in Zurich for facial surgery have also already been developed.
(ETH Zurich), scientists are investigating how flat assembly These can adjust to the individual’s body and can even
kits can be formed into load-bearing three-dimensional grow along with children.
objects by 4D printing a shape-memory polymer in a
multi-material structure under the influence of external
factors. At the centre of the investigations, there is a lifting
element which undergoes changes between two possible
states and can either be drawn in or pushed out. Struc-
tures with several stable positions are also conceivable.
The scientists want to use software to predict the shape
change with precision.

Laser-additively produced microactor for cochlea implants

(Source: Laser Zentrum Hannover LZH)

28
4D textiles

The ability to change shape can also be achieved by

printing a prestressed textile. Here, the deformation is
possible without any external energy being added, as the
required energy has already been stored in the textile.
The self-assembly lab at the MIT has already published
various shape-changing textile structures under the con-
cept “programmable textiles”, and these were created by
printing a prestressed textile. In collaboration with Swiss
designer Christophe Guberan, the scientists have also
developed the “active shoe” as an application example
for the fashion industry. The 2D-treated textile takes the
shape of its final design independently after the printing
process. Designers from Cologne are coming up with
approaches for using the process for manufacturing
acoustically effective 4D textiles. At the RWTH, scientists
led by Professor Thomas Gries are working on applica-
tions for biomedical technology, among other things. By
printing a prestressed textile with a polymer, the wearer
of an exoskeleton should have an easier time when
carrying out various movements thanks to the energy
stored in the textile.

Active shoes project (Source: Christophe Guberan, An exoskeleton supporting the human gripping force. It was
Carlo Clopath, MIT self-assembly lab) produced by 4D printing a plastic on a prestressed textile
(Source: ITA Institut für Textiltechnik at the RWTH Aachen)

29
 2.2 D
 ATA GENERATION AND THE ADDITIVE
MANUFACTURING PROCESS CHAIN

In addition to access to a production system, designing a
component geometry with additive manufacturing technol-
ogy also requires the complete 3D geometry information.
3D CAD programs can be used to create the geometry
information and can convert the three dimensional data
into a facet model (STL, AMF Additive Manufacturing File
Format). The facet model is required for the entire process
of additive manufacturing. The shaped part surfaces are
approximated using triangles (triangulation). As such, a
certain level of imprecision and deviations from the actual
component draft may occur with curved surfaces, depend-
ing on the number of triangles used. The data quantity
increases with the number of triangles and the desired
precision. The triangular facets, which can frequently be
identified on printed components, are the result of the
geometry approximation via the STL format.
In the case of slicing, the STL data is converted into the
layer information (SLI data) required for the additive
process via a separate software application. To make
optimal use of a system’s construction space, multiple
components are distributed on the component plat-
form and aligned in such a way that there is no need for
supporting structures. If, however, supporting structures
cannot be omitted, then these are incorporated into the
slicing process. The necessary software is available from
the systems manufacturers and is delivered as part of the
purchase. Defining the process parameters, such as the
laser speed for SLS or the layer thickness for FLM, can
have a decisive influence on the quality of the component
surfaces and the manufacturing duration. The SLI data
subsequently enables precise control of the machine.

If existing objects or bodies should be utilised to generate

the data, then tactile or optical measuring techniques now
provide the ability to do so (for example 3D scanning).
In recent years, a variety of technologies have been
developed which are capable of generating the data
with different resolution qualities. Working with photos
is the simplest option for 3D scanning. Today, a digital
camera is sufficient to generate a 3D model through the
use of at least 20 photos of an object, and with the help
of software. What is currently the world’s largest mobile
3D data in STL format SLI data with supporting structures
3D scanner is offered by the start-up company botspot
from Berlin, and, depending on the version, has 60 or (Source: Anderl, R.: Additive Manufacturing or generative production
70 integrated cameras or photosensors for scanning process – from prototypes to mass production?” Presentation at the
bodies and large objects. The data collection is possible “Additive Manufacturing” event held by the Hessian Ministry for Eco-
in less than 0.01 seconds. A detail accuracy of 0.1 to 0.2 nomics, Energy, Transport and Regional Development, Hanau, 2014
millimetres is achieved.
The parts may require subsequent cleaning after additive
In addition to working with photos, 3D scanning can also manufacturing of the component geometry, depending
be carried out using light-sections or stripe projections. on the process utilised. For example, the supporting struc-
The procedures are more expensive; however the quality tures need to be removed in the case of some processes.
is generally higher. Lines or striped patterns are projected Components can also be subjected to further treatment
onto an object, the object is rotated and the changes to to improve the mechanical stability or the surface quality.
the angles recorded. Software can transform these into The options range from simply polishing the component
a 3D geometry model. surfaces to the infiltration of porous structures with low-
melt materials, or flocking or metallising to refine the
Regardless of whether the data is created with a 3D CAD shaped parts.
system or by means of optical or tactile techniques, the
subsequent preparation of the data represents a critical
step within the additive manufacturing process. The
reason for this is that errors often occur in the course
of deriving the facet model from the CAD data, which
then delay further processing. Such errors include the
incorrect orientation of individual facets, gaps between
the triangles or duplicated triangulation. These errors
often have to be rectified manually.

30 The world’s largest mobile 3D scanner(Source: botspot)

2.3 P ROCESS CHAINS INTEGRATING ADDITIVE
MANUFACTURING PROCESSES
Since additive manufacturing became prevalent for pro-
totype construction in the mid-1990s, it has also been
utilised for over15 years in toolmaking. Given that these
are generally complex shaped parts, additive manu-
facturing processes have significant cost advantages in
comparison to conventional techniques. Where the direct
manufacturing of tools by means of laser sintering and
laser melting of metals is the focus of the development in
an industrial context, lower cost processes are now in use
among the trades. In this case, the additive production
techniques are generally integrated into a process chain.
Laser melting or laser coat welding can also be utilised
for tool repairs.
Glass-blowing
One variant of the integration of additive manufacturing
procedures is the manual glass-blowing of large objects,
which is almost impossible to carry out with conven-
tional process steps. The glass body is first designed
three-dimensionally on the computer and then printed
as a shaped part using a large-scale FLM system. This is
followed by moulding with plaster and the use of two tool
halves which are then utilised for the actual glass-blowing
and enable highly precise manufacturing of the desired
component. Currently, the use of low-cost 3D printers in
combination with materials such as metal or porcelain has
been opened up experimentally.
Fine casting
When cast parts with a complex shaped part geometry
need to be manufactured as cast metal, for the aerospace
industry or biomedical engineering for example, then
additively manufactured master forms also represent a
suitable means of shortening the process chain. Previously,
the master form had to be created in a complex process.
Today, just a few hours are usually necessary to generate
the model geometry. Stereolithography is the common
choice due to the fact that high surface qualities can be
achieved. Following additive manufacturing, the model is
reworked and a ceramic coating is applied which becomes
the fine casting forming tool after the master form has
been burnt out. The process chain described can create
cast components with a length of up to 1.20 metres. The
shaping accuracy is very high. The deviations amount to
a maximum of +/- 0.2 percent.
Vacuum casting
Function models made of two-component polyurethane
can generally be created in small batches by means of
vacuum moulding. An additively manufactured master
form produced using stereolithography or laser sintering
is suitable for the manufacturing process. This is formed
out of silicone and cut into two halves with a view towards
the necessary parting planes. The casting process takes
place in a vacuum to prevent air bubbles or hollow spaces.
Owing to the high flexibility of the silicone forms, even
undercuts and complex structures can be implemented.
Reaction injection moulding RIM
Reaction injection moulding is a well-established process
in the automotive industry for manufacturing plastic parts
in small batches through the low-pressure injection of
thermoset resins. To manufacture the necessary tool
shapes, a master form first has to be additively produced
on the basis of 3D CAD data, and this form then shaped
with silicone or resins. Depending on the material se-
lection, the low-pressure forming process can result in
different batch sizes. Today, epoxy resin layers with glass
fibre reinforcement are generally selected for particularly
large components.
Silicon tools
(up to 25 – 50 injections)
Hybrid tools
(50 – 100 injections)
Resin tools with fibreglass reinforcement
(200 – 300 components)
Resin tools with aluminium reinforcement
(up to 300 – 1,000 components)
Material selection for the tool and achievable unit quantities
(Source: Materialise)
31
 3.  THE CREATION OF ADDED VALUE
WITH ADDITIVE MANUFACTURING
Additive manufacturing principles have the potential to
partially replace conventional production techniques such
as milling or turning, and develop new value creation
opportunities. In particular when combined with digiti-
sation and increased flexibility of large-scale industrial
production right up to aligning production processes
toward batch size 1, additive manufacturing processes
offer options that traditional processes only provide
to a limited degree. Generative technologies provide
qualities which make them essential for implementing
the ‘Zukunftsprojekt Industrie 4.0’ [Industry 4.0 project
for the future] as part of the German government’s high-
tech strategy.
32
The current keen interest in the possibilities of additive
production and the media attention since 2012 is primarily
due to the convergence of two developments. Firstly, the
manufacturers have improved the manufacturing and
material systems to such an extent that they can compete
with conventional production processes. They can now
be utilised in direct component production for a whole
host of market segments, meaning that in part, traditional
production has been replaced by the processes built upon
it (for example, medical products such as hearing aids).
Secondly, the expiry of a number of patents and prop-
erty rights for a number of important processes such as
filament printing in 2009 or laser sintering in 2014 has
triggered a wave of development and a drop in prices
which has made additive manufacturing attractive for
end consumers. Between 2008 and 2011, the systems
manufacturers in the low-cost sector (systems up to 5,000
US dollars) achieved annual increases of 346 percent.
Hundreds of new manufacturers of filament printers and
desktop laser sintering systems have now appeared on
the market. In 2015, 278,000 low-cost 3D printers were
sold globally (Wohlers’ Report 2016).
The ‘Hype Cycle’, published annually by the Gartner
Incorporation, lends itself well to a detailed examination
of the development and illustrates the technological
developments, the expectations placed on them and the
media interest using a curve graph. In the experience of
market researchers, technical developments follow the
following pattern: When a high level of media interest
combined with a high level of expectation occurs after
a specific technological innovation becomes public, this
is followed by a phase of disillusionment regarding the
forecast potentials and thus a decline in the estimated value
with regard to the financial opportunities. A sustainable
development toward a productive technology does not
take place until after this phase. Every new technology
passes through the hype cycle at a different speed. How-
ever, one assumes a period of at least ten years.
The hype cycle from 2017 clearly shows that additive man-
ufacturing has developed into a promising technology in
the industrial context, and that it is actively being used in
production in a variety of different industries. In contrast,
market researchers believe that the hype of recent years
surrounding the use of 3D printing in the consumer sector
has peaked. In the subsequent consolidation phase the
economic potential and the opportunities will be critically
examined. The productive use of 3D printers in a private
context will not develop until after five or ten years. In
bioprinting technology and the aerospace sector, the
next few years will also see a consolidation of technical
possibilities. The option of the additive production of
replacement human tissue right up to the production of
whole organs is still at the beginning of development, as
is the ability to 3D print consumer goods.

Expectations
Directed Energy
Deposition
3D Printed Surgical Implants
Classroom 3D Printing
3D Printing in Supply Chain
3D Printing in Retail
3D Bioprinting for Life Sciance R&D
Powder Bed Fusion
3D Printing of Medical Devices

3D Printing in 3D Bioprinted Human Tissue

Oil and Gas
Cunsumer 3D Printing
Sheet Lamination 3D Printing of Hearing Devices
Macro 3D Printing 3D Printing for Prototyping
3D Printing in Manufacturing Operations
IP Protection in 3DP
3DP in Aerospace und Defense
3D Bioprinted 3D-Printed
Organ Transplants 3D Printing Service Bureaus
Drugs
3D Print Creation Software
3D Printed Stereolithography
Wearables 3D Scanners
Nanoscale 3DP Material Extrusion
4D Printing Enterprise 3D Printing
3DP of Consumable 3DP in Automotive
Personal Products
3DP Presurgery Material Jetting
3D Printing Anatomical Models Binder Jetting
Workflow Software
3D Printed Tooling, 3D Printing of Dental Devices
Jigs and Fixtures
3D Printed Electronics and Fabrication
As of July 2017

Innovation Peak of Trough of Slope of Enlightenment Plateau of

Trigger Inflated Disillusionment Productivity
Expectations

Time

Years to mainstream adoption:

less than 2 years 2 to 5 years 5 to 10 years more than 10 years obsolete before plateau

Gartner Cycle from 2017 with a special focus on additive production systems (Source: Gartner Inc. 2017)
33
 3.1 MARKET ASSESSMENT
The overall market for additive manufacturing has ex-
perienced significant growth over recent years and by
2022 is expected to have reached 34 billion US dollars
(2016: 6.4 billion US dollars) and a forecast average
growth between 2016 and 2022 of an average of 28.5
percent (Source: Mordor Intelligence 2017). Around 50
percent of the forecast market volume is expected in the
automotive industry, in aerospace and space travel as well
as in mechanical and systems engineering (Source: Melz,
Thyes 2017). Based on their qualitative disadvantages
with regard to the strength and stability requirements,
up until approximately ten years ago, additive technolo-
gies were exclusively restricted to rapidly manufacturing
prototypes (rapid prototyping) and tools (rapid tooling).
Since 2013, the market is undergoing a transformation
and a redistribution in part towards the direct production
of components using additive manufacturing processes.
These developments induce a positively developing
materials market for additive production. In 2016, the
worldwide market for AM materials was at 447 million
US dollars and by 2022 with an average growth of 21.4
percent, should increase to the forecast 1.268 billion US
dollars (Source: Mordor Intelligence 2017).
Production with
traditional machinery
Production with 3D
printers, Scenario I
37500
Production with 3D
printers, Scenario II
16000
11250
2017 2040
ING Bank study reaches the conclusion that 50 percent of
all products will be produced using additive production
processes in the future (Source: ING Bank, October 2017)
34
In the industrial sectors named, 3D printing techniques
have a disruptive nature for a few product areas. The
possibility of reducing the number of parts and saving
materials based on topological optimisation for the same
or even better mechanical qualities allow additive pro-
duction processes to become indispensable for some
components and to substitute traditional production. In
addition, in the next five to ten years, the manufacture
costs for additively produced parts using high-speed
printers are supposed to drop dramatically. The LZN
Laser Zentrum Nord expects a cost reduction of around
100-fold (Sander 2017). Financial experts at the Dutch
ING Bank even state in a study from September 2017 that
by 2040 additive production will take on a proportion of
50 percent of overall industrial production, provided the
growth of investments in additive production systems
continues as it has been in recent years. The authors of
the study also expect that additive production will lead
to a lower growth in trade because work with 3D printing
system requires less labour and the import requirements of
pre-materials and end products from low-wage countries
will decrease (Source: ING Bank 2017).
As well as the substitution of traditionally manufactured
parts with parts manufactured additively, the market entry
barriers, particularly for new companies and start-ups with
innovative business concepts in commercial production,
will be reduced. A large number of new company founda-
tions is expected, where the business models push other
value added potentials to the fore through a combination
of additive manufacturing and digital networking. Idea,
design and construction gain more importance in the
value chain, while production will become a regional and
thus constantly available resource. It is expected that the
international, immaterial flow of goods and the transfer
of data will increase in the future.
2060
3D-printed kit to upgrade a normal bike into an electric bike
(Source: Faraday Motion)
3.2 Q UALITATIVE ECONOMIC FEASIBILITY STUDY
The meaningful use of additive technologies in produc-
tion is already possible to a far greater extent than is
currently being discussed (Cf. Breuninger, J.; Becker, R.;
Wolf, A.; Rommel, S.; Verl, A.: Generative Fertigung mit
Kunststoffen: Konzeption und Konstruktion für Selektives
Lasersintern [Generative production with plastics: design
and construction for selective laser sintering]. Berlin,
Heidelberg: Springer Verlag, 2013). In addition to the
material and machine costs, additive processes can also
reduce a number of other costs which previously resulted
from the necessity of production-oriented design, material
usage and the logistics of semi-finished products and
waste materials in conventional production processes.
Resource efficiency, weight reduction
and assembly work
Since the component complexity does not have an influ-
ence on the production costs, merging design elements
can significantly reduce the number of parts and the
amount of assembly work. This has a positive effect on
both the production costs and also on the possibility of
reducing resource and material usage through complex
hollow structures which are impossible to create using
conventional techniques. Software-supported topological
optimisation by using bionic structural principles allow
an optimised distribution of material to be achieved,
taking into account the mechanical loads. The material
requirement can thus be reduced to a minimum. The
accompanying reduction in weight has positive economic
and ecological effects, in particular for aerospace, elec-
tromobility and in biomedical technology.
LightHinge+: Weight reduction through topological
optimisation (Source: EDAG Engineering GmbH)
Design work and the creation of drawings
Reducing the number of parts also reduces the company’s
overall design work. Although the component construc-
tions must be designed for the corresponding additive
system technology, the additive manufacturing principle
enables designs which were previously only possible with
a significant amount of work. Furthermore, merging parts
also reduces the necessity of creating drawings for the
production. The simplified data management represents
another saving potential for the production industry.
Semi-finished product expenses and waste
management in production
When operating additive production facilities, one can
also expect reduced logistics overheads for the provi-
sion of semi-finished products or materials compared to
those previously required when operating conventional
production facilities. This applies to the provision of
cooling lubricants and also to the disposal of waste ma-
terial resulting from machining production. Furthermore,
neither the clamping devices nor equipment still found
in classical production operations are required.
Using the services offered by 3D printing service provid-
ers or operating low-cost systems in an office or private
context can also create even greater savings potentials
in comparison to the conventional process between
production, assembly, packaging, logistics and sales.
Downloading component data from the internet combined
with additive production and the ability to directly use the
component significantly shortens the classic value chain.
In 2013, researchers from Michigan University discovered
significant savings potentials in comparison to the store
price when comparing 20 printed test objects for prod-
ucts from the electronics and consumer goods sectors.
35
 Power
Weight Cost of Cost of Total RepRap Retail cost Retail cost (total,
consumption
(gram) plastic electricity cost (total, low) high)
Product (kilowatt hour)

iPhone 5 dock 46,2 0,28 1,62 0,03 1,65 3,56 29,99

iPhone 4 dock 19,5 0,1 0,68 0,01 0,69 16,99 39,99

iPhone 5 case (custom) 7,5 0,04 0,26 0,00 0,27 20,00 56,00

Jewellery organiser 19,63 0,08 0,69 0,01 0,70 9,00 104,48

Garlic press 45,01 0,26 1,58 0,03 1,61 5,22 10,25

Caliper 6,37 0,05 0,22 0,01 0,23 6,08 7,88

Wall plate 15.,7 0,07 0,55 0,01 0,56 2,30 22,07

Shower curtain ring (12 units) 33,6 0,24 1,18 0,03 1,20 2,99 2,99

Shower head 71,32 0,27 2,50 0,03 2,53 7,87 437,22

Key hanger (3 hooks) 17,03 0,08 0,60 0,01 0,61 6,98 49,10

iPad stand 11,24 0,1 0,39 0,01 0,41 16,99 49,00

Shoe inserts 39,08 0,13 1,37 0,02 1,38 99,00 800,00

Safety razor 9,9 0,09 0,35 0,01 0,36 17,00 78,00

Pickup 39,31 0,19 1,38 0,02 1,40 9,99 22,99

Train track toy 11,27 0,06 0,39 0,01 0,40 39,48 58,98

Nano watchband (5 links) 9,15 0,05 0,32 0,01 0,33 16,98 79,95

iPhone tripod 12,88 0,08 0,45 0,01 0,46 8,50 29,95

Kitchen roll holder 63,44 0,31 2,22 0,04 2,26 11,20 25,00

Pierogi mould 18,9 0,07 0,66 0,01 0,67 6,95 24,99

Spoon holder 11,6 0,06 0,41 0,01 0,41 4,95 15,00

Savings potential for the manufacture of products based on Open Source design using a 3D printer from American company
RepRap; all costs and prices in US dollars (Source: Michigan Technology University, Joshua Pearce)

3.3 A PPLICATION SCENARIOS AND INDUSTRIES

The following illustration of the technology maturities
indicates that the opportunities additive manufacturing
offers for the main industrial branches are developing in
different ways. It can clearly be seen that additive principles
have already become established in biomedical technol-
ogy. In recent years, these principles have also gained a
certain importance in toolmaking and in the aerospace
industry. In contrast, a major effort will be required to in-
crease the application diversity in the automotive industry
to transfer the systems from their fundamental suitability
for the industry to mass production capability.

Biomedical
Aerospace Toolmaking Automotive
technology

Production at full capacity 10 10 10 10

Production at partial capacity 9 9 9 9

Capabilities of a pilot line demonstrated 8 8 8 8

Production validated in the production environment 7 7 7 7

Production systems manufactured 6 6 6 6

Basic capabilities proven (production-related) 5 5 5 5

Technology validated in the laboratory 4 4 4 4

Feasibility study carried out 3 3 3 3

Production concept identified 2 2 2 2

Functional principle identified 1 1 1 1

Examples • Fuel nozzles • Tools • Air channels • Crowns and

• Structural • Inserts • Formula 1 veneers
elements components • Artificial hip
• Stator joints
components • Medical
(Quelle: Roland Berger, Experteninterviews )
instruments

36
 1100
1000 957
900
800
700
600
474 %
500
400
300
200
100
0
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

Metal systems sales figures (Source: Wohlers’ Report 2017)

Increasing sales figures in metal systems and particularly Market potential

the jump in sales of systems for additive manufacturing
of metallic components between 2012 and 2016, imply
that the industry is preparing for an increase in the use
of additive manufacturing processes.
3.3.1 Vehicle Industry
Vehicle manufacturers number among the first companies
to adopt additive technologies as part of development
processes for rapid prototyping, and have used the tech-
nologies since the mid-1990s. However, in contrast to the
aerospace industry, the quantities are so large that the
integration of additive manufacturing techniques into the
automotive industry’s automated production processes
has not been possible thus far from an economic point
of view. Although complex individual components and
spare parts are already being produced using additive
manufacturing principles in individual cases, mainly in the
plastics sector, widespread usage has not yet taken place.
This is expected to occur in the 2020s with the increasing
productivity of additive manufacturing systems (Source:
Herzog, Ernsberger 2017).
Due to the fact that the mass-production capability of
additive manufacturing processes has only existed to a
limited extent for the automotive industry thus far, hybrid
approaches are being developed for the medium term
and include the integration of laser coat welding into a
classical processing centre (Abele 2014), for example.
Experts believe that industrial 3D printing can only play out
its series advantages if the observations go well beyond
optimisations with regard to structural mechanics and
lightweight construction, and if the additive production
of whole components becomes economically conceiv-
able in the future. The market analysts at Lux Research
calculate a market volume in the automotive industry at
just under four billion US dollars for 2025 (Lux Research
2013). Furthermore, the ability to manufacture ‘on de-
mand’ will transform the value chains and production
will take place precisely where a custom fit component
or spare part is required. According to a 2016 study, the
trend researchers at Frost & Sullivan expect an increase
in the vehicle industry AM market of 34 percent between
2015 and 2020.

The large number of projects from recent years in which

the direct additive manufacturing of vehicle components
including complete chassis elements has been tested
already indicates the approaching entry of additive pro-
duction methods into the automotive industry. EDAG
Engineering GmbH located in Fulda, in particular, has
already drawn attention with a series of additive manufac-
turing concept vehicles such as the EDAG Genesis study
or the prototype “EDAG Light Cocoon”. Above all, the
EDAG designers are expecting additive manufacturing
processes to have the possibility of creating lightweight
structures from nature to reduce the vehicle weight and
the integration of functions.
GENESIS study (Source: EDAG)

37
 Projects and special developments
3i-Print: additively produced front section for
VW Caddy
In summer 2017, the companies Altair, APWORKS, csi
entwicklungstechnik, EOS GmbH, GERG and Heraeus
demonstrated that industrial 3D printing could have a
great deal of potential for the automotive industry in
the future, using the example of an additively produced
front section structure of an old VW Caddy in the joint
development project 3i-PRINT. As well as a particularly
lightweight structure, the team were able to integrate
a large number of functions into the structure and thus
generate real added value. In this way, the additively
manufactured front section structure has details for the
active and passive cooling of batteries and brakes. In the
project, the design for the simulation, calculation and
planning of all process stages were mapped out, right
up to the construction and reworking of the component.
The structure is particularly light and at the same time, stable,
and has many integrated functions (Photo: Haute Innovation)
38
Autonomous shuttlebus OLLI with 3D printed chassis elements
(Source: Deutsche Bahn)
Autonomous shuttlebus OLLI
As part of the future concept “personal transport of the
future”, Deutsche Bahn has been testing an autonomous
bus line on the Euref campus in Berlin since the end of
2016 as a forerunner of self-driving vehicles in public
transport. The test vehicle is the shuttlebus “Olli” from
American company Local Motors, who already caused
a sensation in 2014 with the electric car Strati and its 3D
printed vehicle chassis at the International Manufacturing
Technology Show (IMTS). The shuttlebus “Olli” was the
prize-winner in the 3D Printed Car Design Challenge 2016.
Components of the self-driving minibus were produced
using 3D printing technology.
Cordless screwdriver race 2016
In 2016, the ninth cordless screwdriver race took place,
set up as usually by the Faculty of Design at the HAWK
University of Applied Sciences and Arts in Hildesheim.
The idea behind the competition is for student teams
to compete against one another and develop a vehicle
for one person which is only powered with the energy
from a cordless screwdriver. The theme in 2016 was the
possibilities of using additive production methods when
creating the vehicles. According to the rules, solutions were
permitted which were partially produced with 3D printers
and generative technologies. Here, the load-bearing
structure should travel a distance of at least half a metre
with the help of the 3D printed component between the
axles alone.
Vehicle with a 3D printed load-bearing structure
(Source: University of Applied Sciences and Arts, Faculty of
Design)
Spare part logistics using additive production
The provision of spare parts in the vehicle industry using
3D printing is currently the subject of intense discussion.
Additive technologies would not just be interesting for
vintage cars where it is no longer possible to find spare
parts. Vehicles older than ten years could also find value
in the implementation of a system with additive process-
es. The data would be made available to the workshops
where the desired component could then be printed out
on site when required. There would be no need to keep
parts stored at the site of manufacture. In the project
‘Kfz-Service-Engineering 2020’, Professor Rolf Steinhilper,
who holds the chair for Environmentally-Oriented Pro-
duction Technology at Bayreuth University, is currently
investigating the option of reducing the labour involved
in replacing parts. Instead of exchanging a complete part,
the faulty area could be recorded using a scanner and a
new component produced using additive manufacturing
technologies. This method would save resources and
reduce repair costs for the vehicle owner and the added
value would remain with the workshops. In 2016, Deutsche
Bahn AG started a network of additive manufacturing in
the mobility and logistics sector under the name of “Mo-
bility goes Additive” and is establishing a system for spare
part management. In August 2017, Mercedes Benz trucks
recorded the successful production of a replacement part
for a thermostat cover for trucks of older model ranges.
At Renault, the potential of reducing the weight of trucks
has been investigated since the beginning of 2017 for
the production of components for the Euro-6 motors.
4-cylinder motor block in AISi10Mg. Additively manufactured
in one of the largest laser sintering systems available, an X-Line
2000, with two lasers of 1,000 watts each. Construction space:
80 x 40 x 50 centimetres (Source: FKM Sintertechnik)
3D printed tyres
Car tyres number among the few parts of the vehicle
which have changed very little in both their design and
in their material composition over the last decades. Now,
French tyre manufacturer Michelin has set itself the task
of completely rethinking the tyre within the conceptual
study “Movin’On by Michelin”. The result is a tyre pro-
duced using 3D printing which has a complex, delicate
lightweight structure similar to bones and which has a
3D printed tread. In this way, Michelin wants to make the
tyre adaptable to suit differing road surfaces and climate
conditions. If a change is needed, the driver is led to the
next printing workshop and receives a new tyre profile. All
the printed materials used should also be biodegradable.
3.3.2 Biomedical Technology
Additive manufacturing methods are extremely important
for biomedical technology because they enable the imple-
mentation of individual geometries with a batch size of 1.
This makes it possible to test for operative interventions
in printed models at a manageable cost. Furthermore,
the layered construction allows the option of creating
hollow interior structures, such as those found naturally
in bones, for example. This was not possible with conven-
tional techniques such as milling or turning. Biomedical
technology is the industrial area where the use of 3D
printing technologies has established itself the most for
direct component production. For a few product areas
such as individual hearing aids, it has almost completely
replaced conventional production processes.
Additive processes have the inherent potential to mix
materials in order to precisely adapt shaped parts to the
individual requirements of the human body, whether in
the form of implants, prosthetics or dental prostheses. In
recent years, bioprinting has developed into a new field for
the use of additive technologies. This refers to processes
with the ability to manufacture human or animal tissues
through the 3D printing of cultured cells in an organic
ink by utilising tissue engineering techniques.
39
 Market potential

Over recent years, medical institutions have increased their

investments in systems, services and software related to
additive manufacturing. According to a current study from
the end of November 2017, Gartner trend researchers
believe that three percent of all large hospitals and med- Tailor-made titanium hearing aid shells
(Source: Sonova Group)
ical research institutes have now established resources
(systems, personnel, material, etc.) and knowledge in
this area. Furthermore, the authors of the study also
believe that by 2021, around a quarter of all surgeons Bone drills with integrated cooling channels
will attempt the actual surgery on 3D printed models of
the patient and thus reduce the number of unsuccess- In summer 2017, the Leibniz University Hannover pre-
ful operations. The provision of ready-to-use solutions sented a bone drill with an integrated cooling system in
regarding operation preparation and tools for surgical cooperation with Toolcraft. When using a conventional
training and simulations will be the subject of increasing drill during operations, so much heat can be produced
demand. Market researchers at Lux Research forecast the that healthy tissue can be permanently damaged. Addi-
proportion of biomedical technology compared to the tive manufacturing makes it possible to integrate internal
total market volume for generative production at over cooling channels into the drill. In this way, the undesired
391 million for 2025. This also refers to the manufacture development of heat can be eliminated. Water is fed
and adaptation of prosthetics and implants, as well as into the tool as a coolant during drilling and reduces
applications in dentistry, medical device construction the temperature to a value which is safe for the patient.
and surgical single-use equipment. The market for bio-
printing is not expected to develop until after 2025 (Lux
Research 2013).

Projects and special developments

Individual dental prostheses and additively produced

titanium hearing aid shells

Additive manufacturing methods have established them-

selves in the market for the production of individual dental
prostheses and dental applications such as bridges,
inlays or crowns. Dental technicians value the option to
manufacture solutions tailored to the patient at an af-
fordable cost. Additive production has now also become
accepted for hearing aid shells. These were traditionally
made from acrylic. In summer 2017, Swiss-based Sono-
va Group announced the additive manufacture of the
world’s first hearing aid shell from titanium. This is 15
times more resistant than their acrylic counterparts and
can be designed to be so small that even patients with
a small ear canal can wear a hearing aid, although they
were not able to before.
Additively produced bone drill with integrated cooling
channels (Source: Toolcraft)
3D printer for medications
American start-up Vitae Industries has developed a so-
called AutoCompounder 3D printer which can print
medicines and pharmaceutical jelly pastilles in just a few
minutes, designed for individual patient requirements.
The founders of the start-up want to make the treatment
process of patients much simpler with the personalisation
of medication and dosing and the fast provision of pills.
With the concept of polypills, several active ingredients
can be combined in a single tablet.

40
Bioprinting / tissue engineering
A number of institutes worldwide are currently working
on options for additively manufacturing organs and
human tissue. The medium term goals are to create or-
gans for testing purposes and produce human tissue for
implants. Biological ink containing human cells is used
to construct the organic tissue structure, layer by layer.
Numerous scientific publications have already reported
the reproduction of human skin (Wake Forest University),
the artificial creation of a meniscus (Cornell University),
an auricle (University of Melbourne) and 3D printed bio-
logical materials which break down toxic substances (ETH
Zurich). A team of scientists led by James Yoo has reported
successfully printing a large section of skin on the back
of a pig. However, creating a complete organ consisting
of multiple types of tissue remains just as impossible as
manufacturing a network of functional blood vessels.
In view of this, a mature system for artificially creating
organs will not be available for the next ten to 15 years.
Bioprinters are currently available from manufacturers
such as Envision Tech, Organova and Advanced Systems,
and are primarily utilised for scientific purposes.
Fuel connectors produced using laser melting in Ti6-4 (Source: Airbus)
3.3.3 A erospace Industry
Since components manufactured by means of laser melt-
ing have been able to demonstrate similar mechanical
strengths as those made using conventional milling
technologies, additive manufacturing processes have
become increasingly important in aircraft construction.
In mid 2011, Southampton University announced the first
successful additive manufacturing of an unmanned aircraft.
In September 2014, NASA sent the first 3D printer to the
ISS. In April 2016, Airbus announced the use of the first
3D printed components in an engine for the next gener-
ation of A320. In 2017, parts of the hydraulics of an A380
were produced using additive manufacturing processes.
Over recent years, the large aircraft manufacturers have
increasingly expanded their production capacities with
additive manufacturing methods. Airbus has already
carried out over 250 development projects related to 3D
metal printing and bionics (Sander 2017).
41
 In addition to the freedom in design and geometry, laser
melting also provides faster processing times in compar-
ison to conventional casting or milling processes, along
with reduced tool costs as well as significant savings in
materials, energy and time. Cost reductions ranging up
to 50 percent and a weight reduction of up to 40 percent
were successfully achieved for a number of selected com-
ponents. Whereas milling aircraft components resulted
in a waste quantity of approximately 95 percent, laser
melting reduces the waste to 5 percent. Furthermore,
additive processes provide the opportunity to create a
design aligned with the lines of force and address the
lightweight design requirements even more effectively.
In view of these benefits, Airbus plans to additively pro-
cess approximately 40 tons of metal powder per month
using 100 systems.
The use of generative processes in the aerospace in-
dustry will create new design options with regard to the
complexity and functionality of components. This, in turn,
will have a positive effect on flight behaviour and energy
consumption. This also applies to implementing cooling
channels and the geometry of entire structural compo-
nents for the wings and engines. Aircraft manufacturers
are already examining the possibilities for implementing
designs based on nature’s role models through the uses
of additive technologies.
“There is a good reason why nature has optimised function-
al and lightweight design principles over millions of years
and cleverly minimised resource usage. Airbus is currently
carrying out a structured analysis of the applicability of
these natural solutions,” said qualified engineer Professor
Thor is an unmanned test
engine by which the possibilities
of using 3D printed materials in
aerospace technology can be
tested (Source: Airbus)
42
Dr. Ing. Emmelmann (CEO, Laser Zentrum Nord GmbH,
Hamburg; www.maschinenmarkt.vogel.de/themenkana
ele/additive_fertigung/articles/461436/index3.html). He
sees major potential with regard to structural components
with dimensions of up to one metre, in particular, along
with engine components.
Market potential
Additive manufacturing is primarily of interest to the aer-
ospace industry given that the sector tends to work with
small and medium-sized quantities. High tool costs have
a significantly greater influence on the production costs
than those of the automotive industry’s mass or large-series
production. As such, additive manufacturing processes
are expected to provide a significant reduction in the cost
per unit. Furthermore, experts also expect an additional,
positive cost effect through the transformation of spare
parts logistics toward ‘on demand’ supply. Decentralised
supply networks could safeguard on-site supply and re-
duce delivery times for spare parts, along with downtimes
and inspection times. According to trend researchers at
Gartner, 75 percent of all new commercial and military
aircraft will use additively manufactured components in
the airframe, engines and other components by 2021
(Source: Gartner 2018). Pioneers for additive production
in the aerospace industry are engine manufacturers GE
Aviation as well as Boeing and Airbus.
 Additively manufactured
partition wall Bionic Partition
(Source: Airbus)

Projects and special developments

GE Aviation Partition

As one of the pioneers in the aerospace industry, GE
Aviation has been systematically expanding its produc-
tion capacities since 2011 with additive manufacturing
processes. As one of the world’s largest manufactures
of aircraft engines, the company expects additive man-
ufacturing to provide long-term cost advantages. The
components require less material and are also more
durable than those manufactured using conventional
production processes. By 2020, GE Aviation wants to
have increased the revenue in additive manufacturing
to a billion US dollars. By purchasing the German manu-
facturer Concept Laser (Printing process: SLM selective
laser melting) and the Swedish systems manufacturer
Arcam (EBM electron beam melting) in summer 2016,
the company has secured its access to technology com-
petence for the planned company expansion and, at the
same time, taken over the influence of more than a fifth
of the worldwide market for metal printers.
With the Bionic Partition in 2016, Airbus created the
world’s largest additively produced aircraft component
from metal at that time. This is a partition wall between
the onboard kitchen and the passenger cabin which,
thanks to bionic construction methods, could be made
45 percent lighter than comparable solutions and shall
be used in the A320. The weight reduction was achieved
due to orientation towards the complex growth ratio of
slime fungus which organises its network of veins in a
particularly efficient manner. The joints are designed in
such a way that the organism can always find the short-
est way between several food sources. When designing
the partition wall, the Airbus developers simulated the
growth mechanism and transferred this to the structure.
The weight reduction reduces the CO2 emissions of the
aircraft each year by up to ten tons. Thanks to additive
production and the modular structure, the partition walls
can also be incorporated into existing aircraft cabins. Indi-
vidual components can also be replaced when required.

3D printed hydraulics

In cooperation with TU Chemnitz and Airbus, Liebherr

EOS 25,9 %
Aerospace developed a spoiler actuator valve block in
spring 2017 using 3D metal printing (SLM of titanium
powder) and thus presented the world’s first 3D printed
hydraulic component of primary flight control. It was used
in a test flight for the A380 and is 35 percent lighter than
Concept Laser 16,3 %
the common solution used previously. Liebherr-Aerospace
(GE acquisition)
expects that the weight reduction at a system level will
lead to a significant reduction in CO2 and NOx emissions
SLM Solutions 10,9 % in future aircraft.

Renishaw 6,2 %
Airbus cargo drone challenge
Trumpf 6,2 %
Arcam 5,2 % In 2016, the Airbus group and Local Motors from the USA
(GE acquisition) brought about the first Airbus cargo drone challenge
and searched for future application scenarios for drones
within the framework of an open innovation model. In
concrete terms, they were looking for a drone with a
Others 29,3 % load-bearing capacity of three to five kilograms. In total,
there was a prize fund of 100,000 US dollars. Above all,
the Airbus representatives were enthusiastic about the
number and diversity of the submitted ideas. There was a
Germany
  UK
  Sweden
  total of 425 suggestions from 53 countries. The winner of
the competition was Russian architect Alexey Medvedev
Market spread in metal printing from Omsk with his freight drone “Zelator”.
(Source: Wohlers’ Report 2017)

43
 BIG 3D concrete printer (Source: Imprimere)

3.3.4 Construction Industry and

Architecture

Additive processes (in particular LLM processes) have been

used successfully for model construction for a number of
years. However, the fact that additive technologies may
also be suitable in construction and for manufacturing
architectural structures has become a topic of discussion
once again since ESA announced a project to construct a
space station on the moon. Dr. Behrokh Khoshnevis was
one of the first scientists to develop a concept for the use Concrete 3D printing with steel reinforcement
of additive technologies for construction at the University (Source: Imprimere)
of Southern California in 2004 with the name ‘Contour
Crafting’. The system utilises a portal robot to spray rapidly
hardening special concrete onto the surface in layers to Since then, a number of other model attempts and re-
create buildings according to digital construction plans search plans have become known for establishing additive
in less than 24 hours. In addition to constructing private manufacturing processes in the construction industry.
residences, the application scenarios are visualised for Since 2015, Imprimere AG from Switzerland has been the
situations in which architectural structures have to be con- first supplier of a portal printer for concrete in Europe. In
structed in remote regions in the shortest possible time. 2017, Dr Behrokh Khoshnevis founded Contour Crafting
Series maturity was initially forecast for 2008. However, Corporation to bring the first large-format printer for
difficulties with the strength of the construction material, buildings onto the market in mid-2018 and to offer 3D
along with problems implementing the floor slabs and printing in architecture himself as a service. At the Milan
overhanging structures, have continued to delay the de- Design Week 2018, the first 3D printed building in Eu-
velopmental maturity. There is yet to be a breakthrough rope was presented on the Piazza Cesare Beccaria in the
in terms of series maturity. There is a number of pilot pro- centre of the capital of the region of Lombardy under the
jects or models which could demonstrate the potentials name of “3D Housing 05”. A robotic arm printed their own
of these production principles in construction. developed fast-hardening concrete mixture from cement
supplier Italcementi to create the unusual building struc-
In the context of the NASA Innovation Advanced Concepts ture with kitchen, bathroom, living room and bedroom
Program (NIAC) a robot controlled solution for constructing and a surface of 100 square metres.
a space station on the moon was presented in 2012, and
is based on the previously developed concept. In spring
2014, the Chinese construction company WinSun from
Shanghai announced the successful development of a
simple building structure with the help of an additive
manufacturing process. According to the developers’
statements, it should be possible to construct a building
with the shape and size of a garage in less than 20 hours
for under 5,000 US dollars. The construction of a 6-storey
apartment building using additive manufacturing was
presented by WinSun in January 2015 with a significant
savings potential.

3D Housing 05 – the first 3D printed building in Europe

(Photo: Haute Innovation)

44
 Market potential
The use of additive processes in construction is in an early
phase of development. The market researchers’ analyses
rarely define the size of the market. In his report from 2017,
Terry Wohlers states the market segment for architecture
(including model construction) as three percent of the
overall market of additive production (Wohlers’ Report
2017). It can be expected that in the near future, this
market will experience significant growth.
Projects and special developments
3D printed office building in Dubai
The first printed office building with floor space of 250
square metres including furniture and interior features
was opened after a build period of 17 days at the end of
May 2016 in Dubai, as part of the “Museum of the Future”.
Here, a portal printer with a construction space of 36 x 6
metres was used. The construction costs for the building
were estimated at 140,000 US dollars. The Dubai admin-
istration plans to use additive production technologies
for 25 percent of all new buildings by 2030.
3D printed office building in Dubai (Photo: Haute Innovation)
CONPrint 3D – Large-scale robot fitted with a printhead (Source: TU Dresden)
3D printed pedestrian bridge
(Institute for Advanced Architecture of Catalonia IAAC)
The world’s first 3D printed pedestrian bridge
At the end of 2016 in the city of Alcobendas near Ma-
drid, the world’s first 3D printed pedestrian bridge was
opened. It is 12 metres long, 1.75 metres wide and part
of a walking route in the Castilla La Mancha park. The
microfibre-reinforced concrete structure was topologically
optimised according to biomimetic structure principles
and the quantity of building materials used was reduced
to a minimum. A D-shape portal printer from Enrico Dini
was used for the 3D printing. The development was the
result of collaboration between the Institute for Advanced
Architecture of Catalonia (IAAC) in Barcelona and the
construction materials manufacturer ACCIONA.
CONPrint 3D
The research project CONPrint 3D was carried out at the
Dresden University of Technology in order to transfer 3D
printing into the construction industry. Here, no portal
robots were used; instead, a large-scale robot fitted with
a printhead. For the scientists, this was a question of de-
veloping a quick-hardening special concrete which can
be applied layer by layer and without formwork based
on geometrical data. The team at the Dresden University
of Technology estimate a savings potential of 30 percent
for the solid concrete construction.
45
 Delta WASP 3D clay printer

In autumn 2014 in Rome, the first large 3D clay printer

with a height of 6 metres was introduced with the aim of
creating affordable housing in the poor regions of Afri-
ca. The printer is made up of three moveable rods and,
according to the developers’ statements, can process
several types of clay to form a structural height of up to
three metres. Here, a mixture of clay, natural fibres and
silt is used to build igloo-like structures. The BIG Delta
WASP can now achieve a height of twelve metres.
Robot-controlled metal coat welding process
Since 2015, Dutch designer Joris Laarman and his company
MX3D have been working in collaboration with Autodesk
and construction company Heijmans on a robot-controlled
coat welding process for the additive manufacture of a
metal bridge over a canal in Amsterdam. During this
process, conventionally available welding wire is melted
and applied in layers. The speed of the process is set
in such a way that cooling and hardening take place as
fast as is necessary to eliminate the need for a support
structure for overhangs and undercuts. The 3D printed
metal bridge is expected to be finished in autumn 2018.
The bridge will be installed in 2019.
3D printed room corner from the project “10 Smarta Kvadrat”
(Source: BLB Industries)
10 Smart Kvadrat
In 2016, the Swedish systems manufacturer BLB Industries
presented a large-scale printer for plastic components
based on fused granular fabrication technology (FGF)
which can be adapted to each application in terms of
dimension and execution. In the context of the model
project “10 Smarta Kvadrat”, a building component as a
wall structure with an embedded window made from the
polymer PLA with a 20 percent wood fibre composition was
3D printed in collaboration with a Swedish construction
company. The additive manufacturing process, carried
out with a two millimetre nozzle and with a scope of ten
components, lasted a total of one week.

3D printed metal bridge (Source: MX3D, Amsterdam)

46
3.3.5 Electronics
Additively produced and 3D printed electronic systems
are being introduced in numerous areas of application:
in biomedical technology, in the development and pro-
duction of electronic devices, in vehicle construction, in
the aerospace industry, for mobile digital systems and
in the energy sector. Certain functions and properties
can be created much quicker and more simply using
3D printing than they can with traditional manufacturing
methods. This includes applications with electrically con-
ductive structures as well as insulating areas or sensory
components. Above all, additive production in electronics
is expected in all areas where economic advantages are
created compared to the previously used methods with
regard to reductions in component size and weight. In
the biomedical development processes in particular, the
quick provision of circuit boards is highly relevant.
Market potential
Die 3D-gedruckte Elektronik ist ein Markt, der sich in der
3D printed electronics is a market which should develop
in a very positive manner over the next decade. A mar-
ket volume of one billion US dollars is forecast for 2025
(Harrop 2015). The applications suggest a strong reference
to traditional two-dimensional printing techniques. Here,
bent, but still two-dimensional, surfaces are printed, but
no three dimensional objects are created.
Projects and special developments
3D printed antenna

Neotech AMT GmbH in Nuremberg specialises in the

development of 3D printers and processes for electronic
applications. By using a patent-protected technology,
the additive production systems can build electronic
components and systems onto even and complex three-di-
mensional shaped substrates. The area of application
of Neotech’s technology also covers injection-moulded
circuit carriers (moulded interconnect devices, 3D MID),
integrated sensors and materials to protect and connect
sensitive electronics. An application example is a 3D
printed antenna for mobile communication applications.

Printed battery (Source: Fraunhofer ENAS)

A vast number of methods and technologies have been

developed to allow the additive application of electrically
conductive inks or pastes through screen printing, dis-
persion processes and ink or aerosol jetting. In addition,
additives embedded in plastic objects are important for 3D
printed electronics. This includes electrically conductive
filaments where it is possible to create simple electrical
systems on conventional FLM printers. The next devel-
opment boost for additive production in electronics is
expected in graphene-based filament printing (Frost &
3D printed electronics for the automotive industry
Sullivan 2016). Battery systems are expected to have 3D
(Source: Neotech AMT GmbH)
printing possibilities. At the moment, scientists are work-
ing on AM methods for manufacturing nano electronic
solutions. The first 3D printer for electronics came onto
the market in 2015.

47

Voltera V One – Circuit board printer for printed electronics
(Source: Voltera)
Voltera V One circuit board printer
With a printer for conductive pastes and inks, a student
developer team at the Canadian Waterloo University won
the race for the acclaimed James Dyson Award at the end
of 2015. The investment capital of £ 331,000 collected via
a Kickstarter campaign was used to bring Voltera V-One
onto the market. The quick provision of circuit boards
is particularly important for the development of digital
devices and biomedical applications. Small changes to the
design of switches mean a lot of labour-intensive proto-
types when conventional methods are used. With Voltera
V-One, the effort required for the creation of versions of
electronic switches can be reduced to a minimum in the
development phases of the electronic industry. With the
V-One, a conductive liquid with silver particles is applied
onto conventional platinum material. A second, non-con-
ductive, liquid then ensures that the layer is electrically
insulated between the individual layers.
3D printing technology for the integration of
electronics
In 2017, the University of Sheffield in cooperation with
Boeing developed an additive manufacturing process
to integrate electrical components, optical systems or
structural elements into a component during 3D printing.
Using this method, complex functional elements can be
manufactured in one production stage in a way which saves
time and costs. The development was registered at the
patent office under the name of “Thread”. The function
has only been tested on plastic up until now. According
to the Boeing development engineers, however, the
process is also transferable to other 3D printing systems.
The scientists’ primary aim was to be able to create com-
ponents with interruption-free cables, filaments and wires
in all three dimensions and to give additively produced
parts additional functions.
48
3D printing for permanent magnets
The creation of permanent magnets with a strong magnetic
effect is today’s state of the art technology. However, the
creation of complex geometries with a specific magnetic
field effect is quite a challenge for scientists and producers.
Shaping processes such as injection moulding cannot
be used for reasons of economy. Scientists at the Vienna
University of Technology developed a 3D printer in 2017
to produce permanent magnets with custom magnetic
fields in an additive manufacturing process for the first
time. Special filaments for the magnet printer were de-
veloped out of a magnetic micro-granulate, which was
bonded in a polymer matrix. The magnetic particles are
so finely distributed in a thermosetting plastic that the
filament softens in a heated nozzle and can be applied
layer by layer. The new printer produces permanent
magnets which consist of around 90 percent magnetic
material and ten percent plastic. After shaping, the not
yet magnetic material is placed under a strong external
magnetic field and the permanent magnet is created.
During this process, the field can be set specifically in
terms of effect.
3D printed permanent magnets
(Source: Vienna University of Technology)
Fluidic force microscopy
An additive production process is currently being re-
searched under the name of fluidic force microscopy
(FluidFM) for extremely fine metallic structures. In the
future, this will allow micro-components for biomedical
technology, the electronic industry and the watch indus-
try to be manufactured. Using a computer-controlled
micropipette, a copper sulphate solution is applied to a
conductive substrate. When electrical current is applied,
pure copper is separated electrochemically. With a pixel
size of just 0.8 microns, this process can produce compo-
nents which are half as thick as a human hair (Caviezel,
C. et al. 2017).
 Aerosol jet printing
Mit dem Aerosol Jet Printing der US-amerikanischen Fir-
With aerosol jet printing created by American company
Optotec, conductive, di-electric semi-conductive and
biological inks available on the market can be printed
onto a number of flat and three-dimensional substrates
made from plastic, ceramics or metals. The conductive
inks are transferred into a cloud containing the printing
medium using an atomiser. The cloud is separated from
the substrate using a nozzle. A protective environment
surrounding the cloud ensures that the atomised ink re-
mains focused and prints them out in one to five micron
droplets onto the substrate.
Thick aerosol
Sh
ea
3.3.6 Consumer Goods
The authors of the study “Predicts 2018: 3D Printing and
Additive Manufacturing” by American analysis company
Gartner Inc. states that by 2021, around one fifth of the
100 leading companies in the consumer goods industry
will use additive production processes for the develop-
ment and manufacture of their products. The main focus
will remain on fast prototype construction to shorten the
development cycle and minimise the investment risk for
new developments. The Gartner market researchers also
expressly point out that additive production processes
will not replace traditional mass production in the con-
sumer goods industry with regard to the cost structure.
It will only be used where product adjustments offer a
significant added value and where the user expects a
custom product feature.

Section 1:
thi

Atomising Section 2:
Market potential
ng

the ink Focusing

ga
s in

the aerosol
let

Gas inlet In some areas of the consumer goods industry, supply

chains will significantly change under the influence of
3D printing technology. New business models will arise,
which offer a clear advantage over the previous range.
Companies expect significant savings potentials through
Ink Ray focused
3 to 5 mm distance
at < 10μm additive production procedures, particularly in spare part
Section 3: Substrate logistics. In 2017, some DIY shop chains started to offer
Coating 3D printing services to their customers.
process

The aerosol jet printing process (according to OPTOMEC,

Fraunhofer ENAS)

3D printed, custom LUMIX camera casing

(Source: Materialise)

49

Futurecraft 4D – sole manufacture using the CLIP process
(Source: Adidas)
Projects and special developments
Futurecraft 4D
As one of the first sports shoe manufacturers, Adidas
started to use additive production processes to manufac-
ture soles individually tailored to the athlete in 2015. In a
first project with 3D printing service provider Materialise,
the running movement of an athlete on a treadmill was
measured, the data of the foot impressions captured and,
using a laser sintering process, the individual intermediate
soles were custom produced from flexible polyurethane
for the sports shoe. These corresponded exactly to the
contours and pressure points of the runner and adapt-
ed to the movement processes. In spring 2017, Adidas
announced that it would be working in partnership with
Californian company Carbon 3D to additively manufac-
ture the midsole of the Futurecraft 4D shoe using CLIP
technology (Continuous Liquid Interface Production). The
digital light synthesis process cures a resin system using
the influence of light. By the end of 2018, a series of more
than 100,000 pairs of shoes should have been produced.
3D printer as a
modular system for children
(Source: fischertechnik GmbH)
50
AM printing services in DIY shops
Some large DIY shop chains in Germany started to establish
3D printing services for their customers in 2017. To do
this, internet platforms were developed which allow the
customer to order components in various materials such
as polyamide, alumide (powder mixture from PA12 and
aluminium), ceramic, ABS or steel without prior knowledge.
Either already available 3D-CAD data of the component
can be uploaded, scaled and processed, or enquiries can
be sent based on sketches and drawings such as images.
The necessary data for 3D printing are then generated
from these in collaboration with a service provider.
3D printed toys
Additive production possibilities offer diverse potential
for the toy industry in developing new business and sales
models. This becomes particularly clear with the incor-
poration of the customer in helping to design the toys. In
this way, some providers have entered into partnerships
with 3D printing service providers in recent years and
offer children the chance to design and print their own
toys at the computer in toyshops. Children have the op-
portunity to help create their own toy on the computer
and to use additive manufacturing methods to produce
this on site (Leupold, Glossner 2016). In spring 2016,
the Fischerwerke presented a 3D printer as a modular
system for children at the Nuremberg toy fair. This gives
adolescents simple access to technology and allows them
to print out building blocks and elements themselves. On
the fischertechnik eLearning portal, children can obtain
printing data, component examples, didactic accompa-
nying information and videos.

Image: The world’s first 3D printed cantilever chair “Cellular
Loop” (Design: Anke Bernotat)
3.3.7 Design, Jewellery, Interior
Additive manufacturing has always been highly attractive
for the creative sector. The reason behind this is that
additive technologies seem to enable the implementa-
tion of designs which previously required an extensive
knowledge of manufacturing processes or which were
simply impossible to implement due to technical or
financial restrictions. Additive manufacturing even per-
mits products and concepts with complex geometries,
hollow spaces, undercuts and movable components to
be created. This changes the way in which the designers
and product developers work due to the fact that only
a limited knowledge of production-oriented design is
required. As a result of new material developments,
additive technologies are currently being utilised in the
fashion industry.
Winner of the 3D Pioneers Challenge 2017 –
Project T.O.S.T. Topology Optimised
Skateboard Trucks (Source: Philipp Manger,
Ernst-Abbe-Hochschule Jena)
The availability of construction kits and information about
the design and operation, along with the software and
component data, has resulted in a flood of developments
by designers and architects. Representatives of the creative
economy have developed a vast array of new systems
and patented some of these, transforming them into a
successful business model. In this way, developments for
4D printing mainly came from designers and architects
at the MIT media lab. The development of a process for
robot-controlled metal coat welding for the manufacture
of a bridge came from designer and artist Joris Laarman
from Amsterdam. The world’s first 3D printed cantilever
chair “Cellular Loop” was designed by designer Anke
Bernotat from Fulda and produced using laser sintering
technology.
Market potential
Additive manufacturing offers an enormous range of
opportunities for the creative and design sector. As such,
a separate market attributable to members of the crea-
tive economy will arise in the future and possess its own
products, scenarios and business models. This will focus
less on business processes in terms of mass production as
per conventional understanding and more on solutions
with an individual or customisable design, functionality
and manufacturing method. In the jewellery industry, in
particular, additive manufacturing processes are already
utilised as an alternative to the conventional process
chains. In 2015, the 3D Pioneers Challenge was started
in cooperation with Rapid.Tech to display the potential of
the design sector by using additive manufacturing pro-
cesses. The competition takes place in Erfurt every year.
51
 Projects and special developments
Open rugs
In April 2017, the Dutch designers at Studio Plott first
presented a 3D printed rug with a structure than can be
customised on the computer. The 3D printed pattern is
given a coating of flock fibres after the additive manu-
facturing process which produces the approximate soft
texture of a textile surface.
3D printed rug with flock coating
(Design: Studio Plott)
52
Ceramic printing
Dutch designer Olivier van Herpts has developed a 3D
printer for large ceramic parts based on Delta Tower
technology. To do this, he fitted the printer with an ex-
truder for paste-like materials. With this, he can produce
ceramics with a maximum height of 80 centimetres and
a diameter of up to 42 centimetres.
3D glass printing
Probably one of the most spectacular developments in the
generative processing of glass materials was presented
at the end of 2015 by the Mediated Matter Group at the
MIT. 3D glass printing (3DGP) follows the FDM process
principle, however rather than melting plastic materials,
glass is melted when heated to suitably high tempera-
tures. A team led by Professor Neri Oxman integrated an
extruder into an oven, allowing the glass materials to be
incorporated and processed. The system has produced
expressive bowls and vases with impressive light-reflec-
tive qualities.
The first glass printer was brought onto the market at
the start of 2017 by Israeli company Micron 3DP. This
system can additively process borosilicate glass from
glass specialists Schott from Mainz.
Cellular Loop
In Kooperation mit dem Fraunhofer UMSICHT hat die
DeIn cooperation with Fraunhofer UMSICHT, designer
Anke Bernotat examined the lightweight construction
potential of nature for weight optimisation and introduced
the world’s first additively produced cantilever chair. The
furniture was subdivided into identical cuboid cells along
its contours and a numerical simulation of the mechanical
qualities was carried out. The result is a geometry, created
using the selective laser sintering method, which is ideally
set up to suit the effective forces.
3D weaver loom for manufacturing zig-zag weave with auxetic
features (Design: Oluwaseyi Sosanya, Photo: Zuzanne Weiss)

3D weaver loom Rapid liquid printing

Durch Kombination von 3D-Drucken und Weben pro-
duziThrough a combination of 3D printing and weaving,
designer Oluwaseyi Sosanya produces hexagonal woven
structures with auxetic features with his 3D weaver loom.
These features mean that the woven structure can resist
impacts of more than 300 grams and are particularly
suited to dampening recurring external stresses. The
zig-zag weave is light and extremely flexible, and suitable
for applications in biomedical technology, vehicle and
sportswear industries.
Scientists at the Massachusetts Institute of Technology (MIT)
selected a similar approach to InFoam printing. During
rapid liquid printing, however, material is not incorporat-
ed into soft foam, instead, a gel is used as a supporting
material basis for printing into the space. The gel allows
structures to be printed into the space completely without
restrictions. After a few minutes, the printing material
reacts with the gel and grid structures appear which can
be put to good use in furniture construction.

InFoam printing

In cooperation with chemistry company Covestro, de-

signers Dorothee Clasen, Adam Pajonk and Sascha Praet
have developed a process to influence the properties of
flexible foam by way of a robot-supported injection of
structures from a two-component polyurethane synthetic
resin. The InFoam printing can be used in an array of dif-
ferent applications and allows free-moving solid bodies
to develop in the foam which have a partial stiffening
effect. The various degrees of hardness can be used to
improve the sitting or lying properties of upholstered
furniture and mattresses. Under pressure, for example,
the fabric is able to bend.

Rapid liquid printing

(Source: MIT self-assembly lab, Christophe Guberan)

Liquid printed bag

(Source: MIT self-assembly
lab, Christophe Guberan)

InFoam printing (Design: Adam Pajonk, Dorothee Clasen,

Sascha Praet; Source: Covestro)

53
 Metsidian table (Design: Janne Kyttanen)
Metsidian table
Mit dem Metsidian Table kreierte der finnische Designer
The metsidian table is a piece of furniture made from
copper and the volcanic rock obsidian, created by Finn-
ish designer Janne Kyttanen using a combination of a
3D printed structure and explosion welding. Explosion
welding is used if materials can only be welded when
high temperatures are used. While the melting point
of copper is just under 1,100 degrees Celsius, volcanic
stones usually only melt in temperatures well above 1,400
degrees Celsius.
54
3.3.8 Food Industry
In 2014, the market for 3D printing processes also ex-
panded in the food industry as a result of so called food
printers. The costs for the systems lie in the four-digit
range and, thus, operating a system is currently only
profitable in the restaurant and catering industry, and
for creating unique products. This includes customised
baked goods, cakes or pralines, along with sculptures
made of sugar or chocolate. The Italian food company
Barilla has launched a system for 3D printing of pasta. In
the USA, a system is being developed to produce meat
by printing animal muscle cells.
Market potential
It is very difficult to assess the development and overall
potential as the market is still in its infancy. Food printers
will enable the restaurant and catering sector to implement
new business models which will include event gastronomy.
In 2016, a start-up company in London opened the first
pop-up restaurant for 3D printed food under the name
of Food INK. Private usage is definitely linked with the
price of the system and the availability of the ingredients.
Dutch scientists mainly see food printers as having the
potential to provide foodstuffs with personalised nutrient
contents for the medical sector. Thus, special nutrients or
omega-3 fatty acids could be added to foods in the future.
Foodstuffs could also be printed using more sustainable
caloric sources by processing algae proteins instead of
resource-intensive animal proteins, for example. In addi-
tion to the economic potential, this would also serve as
an opportunity to reduce greenhouse emissions resulting
from livestock farming.
 Projects and special developments

Sugar Lab / ChefJet

In autumn 2013, 3D-Systems became one of the first major

systems manufacturers for additive production to enter
into the emerging food printer market. The company
took over Sugar Lab in Los Angeles, a company run by an
American designer and an architect, after they created a
sensation in May 2013 when they presented an exhibition
of printed sugar sculptures. The two designers created
the sculptures with a colour jet printer and utilised sugar
powder together with an edible, coloured binding agent.
In January 2014, 3D Systems presented the first ChefJet Pizza printer Foodini (Source: Natural Machines)
at the CES electronics exhibition in Las Vegas. The basic
variant is primarily offered to bakeries, confectioners and
for designer gastronomy.
Shape-changing pasta

Foodini / Natural Machines
After NASA presented the concept for a pizza printer
in 2013, the start-up company Natural Machines from
Barcelona set out to launch and market the first pizza
printer, the Foodini. In addition to the Italian speciality,
the Foodini can essentially be used to prepare any type
of food which requires a paste-like mass, or where the
ingredients can be melted by means of heat. As such,
the Foodini is also suitable for producing baked goods
such as cookies, chocolate sculptures or dishes made with
minced meat. The ingredients are supplied in a heated
stainless steel cylinder and applied via a nozzle. Every
individual ingredient is contained in a cartridge which
is pressurised in accordance with the consistency of the
mass. Recipes can be downloaded from the Internet.
At the MIT in the USA, fields of application for shape-chang-
ing 3D printed geometries are currently being examined
for the food and transport industries. The idea is to print
pasta dough with different proportions of gelatine and
thus create shape-changing pasta shapes. Once the
printed pasta comes into contact with water, the mass
absorbs moisture. As gelatine expands to a great degree,
the printed pasta mass reacts by changing its shape. In
the 3D printer, different geometries can be created layer
by layer which ensure that the flat pasta mass stands up
in water. With this development, the MIT scientists have
a reduction in transportation costs in the food industry
in mind. For example, in a packet of macaroni from the
supermarket today, 50 percent of the packet volume is air.

Pasta printer / Barilla

In collaboration with the Dutch research institute TNO in

Eindhoven, Italian pasta manufacturer Barilla developed
a 3D printer for pasta and presented this to the public in
mid 2016. However, the device is not intended for mass
production, but rather private usage or at restaurants. In a
manner similar to a coffee dispenser, the printer operates
with dough cartridges which contain the ingredients for
a variety of different pasta types. With the pasta printer,
15 to 20 pieces of pasta can be manufactured within two
minutes, the shapes of which cannot be achieved with
traditional methods.

3D printed shape-changing pasta

(Source: Massachusetts Institute of Technology / MIT)

55
 Candy2Gum

Polyvinyl acetate solid resins are important components

of chewing gum raw mixtures. Wacker Chemie has now
developed recipes for chewing gum which are suitable for
processing with a 3D printer. Using an innovative boiling
process, water-based, fatty and natural ingredients are first
processed into chewing gum. This then allows them to be
shaped into a 3D form with the specially developed 3D
printer of the company. The process has been optimised
to ensure that even the soft components of chewing gum
can be processed. This allows natural ingredients such as
milk, cacao, coffee, caramel, chocolate or plant extracts
to be incorporated into the chewing gum.
Mealworm printer from the pilot project “Falscher Hase –
Bugs’ Bunny” (Design: Carolin Schulze)
Print a Drink

The world’s first 3D printer for liquid foodstuffs and drinks
was presented at the end of 2016 by Austrian Benjamin
Greimel. Drops of oil are injected into a thick liquid drink
using a robotic arm. This creates 3D cocktails as customis-
able creations in the context of forward-thinking molecular
gastronomy. “Print a Drink” was awarded a prize in the
3D Pioneers Challenge in 2017.
Mealworm printer
Almost a fifth of the greenhouse gases responsible for
climate change are produced in livestock farming. One of
the main reasons for this is the inefficient use of biomass
for mammals and fish. An alternative would be to obtain
meat from insects. According to a study conducted by
the Food and Agriculture Organisation, 1,400 species
of insect could secure a worldwide food supply. In Asia,
research work is already being carried out on this issue.
Designer Carolin Schulze was given the national ecode-
sign award in 2015 for developing an insect printer as a
possible solution for sustainable and ethically responsible
nutrition. First, the designer produces a malleable mass
from the insects and transforms this into an attractive
shape using the printer.

Print a Drink (Source: Benjamin Greimel, Philipp Hornung,

Johannes Braumann; Photo: Philipp Moosbrugger)

56
3.4 3 D PRINT SERVICE PROVIDERS AND
CONTENT PLATFORMS
Given the high purchasing costs for industrial systems
using additive processes, service providers have already
become established on the market some years ago.
Whereas before they worked primarily for company de-
velopment departments which did not wish to operate
their own systems, the increasing interest in direct additive
production for the creative economy and among private
individuals has now seen online platforms become es-
tablished on the market. 3D parts data can be uploaded
and the construction ordered with a specific material
and the desired colour. A number of service providers
also support the generation of the required data and
offer contacts with designers. The online print services
generally also provide an overview of the available final
designs which can be selected and customised. Several
print service providers (such as 3 Faktur, Materialise) also
provide online support for the pricing or offer to create
3D print files based on 2D sketches (such as Pagu 3D).
3D-Colorprint: www.3d-colorprint.de
3 Faktur: www.3faktur.com
Fabberhouse: www.fabberhouse.de
Materialise: www.imaterialise.com
Pagu: www.pagu-3d.de
Ponoko: www.ponoko.com
Sculpteo: www.sculpteo.com
Shapeways: www.shapeways.com
Trinckle: www.trinckle.com
Overview of some online 3D printing service providers
In recent years, the platforms have expanded increasingly
and have a more user-friendly design. In addition, the
business model of a number of platforms is developing
in a direction which offers new sales opportunities for
product designers and artists. These portals enable them
to upload and sell the data while paying a commission to
a third party. In some cases, it is also possible to download
the 3D blueprints and modify them to a certain degree.
In addition to the online print service providers, content
platforms have also become established on the Internet,
and allow users to store and share their own 3D designs
and component plans. A search function can be used to
find the desired design for one’s own print from among the
thousands of object datasets. Generally, one or more STL
files are available for downloading. On some platforms,
the source data is also available in addition to the STL data.
Archive 3D: www.archive3d.net
(over 40,000 datasets,
focus: furniture, interior, lamps, accessories)
Blend Swap
(over 20,000 datasets,
focus: figures, interior, accessories)
GB3D Type Fossils: www.3d-fossils.ac.uk
(over 2,000 datasets,
focus: 3D models of fossils)
GrabCAD: www.grabcad.com
( over 2,580,000 datasets,
Focus: technical assemblies and components)
Smart Exchange: exchange.smarttech.com
( over 5,000 datasets,
Focus: biological processes, organs,
technical components)
Thingiverse: www.thingiverse.com
(over 1,000,000 datasets,
focus: small parts, accessories, lights, games)
Trimble 3D-Warehouse: 3dwarehouse.sketchup.com
(over 5,000 datasets, mostly 3D architecture)
TurboSquid: www.turbosquid.com
(over 300,000 datasets, buildings, 3D architecture,
objects, animals))
Yeggi: www.yeggi.com
( over 1,300,000 datasets,
focus: technical components, small parts, accessories)
Overview of a few content platforms
57
 MAGIE – experiment space, implementation workshop and creative meeting place for Gießen (Source: Daniel Körber and Christian Hain)
Local print service providers are now present in a number
of cities, in addition to the online service providers. Their
services range from a complete service with multiple
systems to do-it-yourself (DIY) print shops, as well as
FabLabs and 3D Hubs. 3D print shops generally sell both
finished printed components as well as printing services
for customers. In the case of DIY print shops, it is possible
to rent a 3D printer and carry out the printing process at
home or at the office.
The idea of the FabLab originates from the MIT Media Lab
in Boston. The first FabLab (fabrication laboratory) was
opened here in 2001 under the supervision of Prof. Neil
Gershenfeld. This refers to a small workshop with its own
printers and other systems such as milling machines or
laser cutters which can be used by a community utilising
open source software together or under the supervision
of voluntary helpers. The community idea ensures that
every single individual has access to all of the technical
options of additive manufacturing and also receives the
necessary software. The individual FabLabs are run as
associations, are organised regionally and form a network
with other FabLabs.
58
A code of conduct and self-commitment for all of the
open workshops are compiled in the FabLab Charta
which is published by the Fab Foundation. Open FabLab
appointments are generally arranged for beginners so that
everyone can use the printers and software independently.
In April 2014, a FabLab was opened in Darmstadt close
to the Fraunhofer IGD. Makerspaces have also started up
in Wiesbaden, Gießen (MAGIE) and Frankfurt (tatcraft).
A FabLab with the name FabLab FFM is also planned
for Frankfurt.
The community idea not only extends to the workshops
that maintain the printers, but also to private individuals
who have purchased an additive manufacturing system but
do not utilise it around the clock. The 3D Hubs business
model originates from the Netherlands. A platform lists
3D printer owners who allow other people and companies
to use the system for a fee. This allows the systems to be
used to capacity and also enables the printer owners
to generate revenue. With every order processed via
3D Hubs, the platform operators from Amsterdam also
earn revenue due to the commission of 15 percent of
the printing price. More than 7,200 systems operators
are now registered worldwide.
3.5 L EGAL ISSUES IN THE CONTEXT
OF ADDITIVE MANUFACTURING

DI S C LA I ME R
It is explicitly stated that the information provided in this
chapter represents neither a conclusive presentation nor
individual legal advice. The information solely serves
to illustrate current issues and perspectives in order to
provide an overview of the problems described and
the context. The information is in no way intended to
replace individual legal consultation from appropriately
qualified persons.

An increasing number of questions regarding the legal Copyright

conditions have arisen, in particular since the emergence
of the first platforms for sharing 3D printing data. Although Copyright serves to protect a person’s ‘intellectual prop-
the legislation regarding the development, sale and use erty’ which reaches a certain threshold of originality.
of three-dimensional objects and products has a broad This refers to works of literature, photography, film and
scope with the copyright, brand, patent, utility model and music, as well as scientific works and free and applied art.
design laws as well as the legislation about the protec- Copyrights can be asserted without having to register a
tion of personal data, the digital exchange and additive creation as such with the patent and trademark office.
replication of components contains a number of risks of In the context of additive manufacturing, this primarily
legal violations of which the user may be unaware. These applies to three-dimensional works of art and sculptures,
include claims for damages in the event of failure of an along with design objects and pieces of furniture. Cop-
additively manufactured component, the use of privately ying for private use may be permissible, provided that
printed objects on commercial premises or scanning a no data which has obviously been published illegally is
legally protected product to generate data for 3D printing. utilised. Depending on the case at hand, multiple copies
The distribution of data for constructing weapons via the are permissible. However, sending the data to a service
Internet represents the most obvious legal problem. The provider is not permitted. Duplication for commercial pur-
issues generally do not differ with regard to the private poses without the permission of the originator can result
or commercial use of a printed component or product in prosecution. Even the digitisation of a work protected
due to the fact that copyright and trademark laws apply by copyright represents a copyright-relevant action. Only
equally in both cases. Legal violations can occur when the copyright owner is permitted to obtain or scale digital
recording the data of a protected product, when sending data from his or her own work (VDI: Statusreport “Additive
or accessing three-dimensional data and also through the Fertigungsverfahren”, Verein Deutscher Ingenieure e.V.,
additive manufacturing of a component geometry or its September 2014). The copyright does not expire until 70
sale. In a working report from the European Parliament’s years after the copyright owner’s death.
legal committee (JURI) from 2017, the establishment of a
global database of 3D printable objects was suggested as
a possible solution approach to monitoring the reproduc-
tion of components protected by copyright. In addition, a
legal upper limit for the number of private copies could
be set for 3D objects or a tax levied as compensation for
copyright violations. In the future, 3D printed components
will be retraced, identified and authenticated with the use
of forensic marks. These can be introduced to the object
data as a digital signature before the printing process and
captured by 3D scanners after the additive production
process for approval. Changed legal conditions for ad-
ditive manufacturing companies have also existed since
the General Data Protection Regulation (GDPR) came into
force. This is because personal data is not just processed
in service provider and personnel management during the
additive manufacturing process, but can also be present
in order fulfilments characterised by individual product
development and data-driven production. Corresponding
measures and adjustments of the affected processes are
necessary to meet the new data protection requirements.

59

Design rights
In addition to copyright claims, the design of products and
consumer goods can be further protected by designers
or a company through registration with the patent and
trademark office. The registered design is protected for
a period of 25 years. Novelty and uniqueness are pre-
requisites for the registration but are not checked by the
patent and trademark office. The reference to a registered
design can prohibit both the duplication of a product,
consumer good, designer and/or fashion article, along
with the marketing or use thereof. As such, these design
rights also have a strong influence on issues regarding
the legal framework for additive manufacturing.
Utility model protection and patent law
Patents and utility models are industrial property rights
which allow the inventor and/or company the protected
commercial use of a technical invention. Whereas granting
a patent requires a significant level of invention, utility
models only represent an inventive step. As such, the
protective framework for patents is significantly greater
and the maximum protection duration of 20 years far
exceeds the ten years for utility models. Possible patent
rights should be checked when reproducing parts or
components of a product by means of additive manu-
facturing. After the expiry of a patent, the technical solu-
tions published in the course of the patenting process
become freely available. The issue of whether copying
design features of a product represents a direct breach
of patent has not yet been resolved definitely. In view
of the prevailing jurisprudence, the concrete copying
of geometry data appears to be sufficient to represent
a breach of property rights (VDI: Statusreport “Additive
Fertigungsverfahren”, Verein Deutscher Ingenieure e.V.,
September 2014).
60
Trademark law
Trademark law enables the protection of the labels of
a product or a company in the form of images (design
mark), words (word mark), their combination (word and
design mark) or graphical illustrations in two-dimensional
and three-dimensional form. Products and goods with
protected trademarks may not be reproduced, offered
or marketed in an identical or similar form. Due to the fact
that the protected marks on a product may be reproduced
as a result of the increasing popularity of 3D printers and
scanners for recording 3D geometries, legal violations
cannot be excluded.
Thus far only a few legal violations within the context of
additive manufacturing are known. However, in view of
the growing market for additive manufacturing during
the coming years, this could grow in a manner similar to
the situation observed in the music and film industry at
the beginning of the millennium. The European Court of
Justice has clarified that the operators of internet platforms
cannot directly be held liable for making available the
technical means for the trademark infringing goods. The
Federal Supreme Court has also rejected their aiding and
abetting liability for trademark violations of third parties
(Leupold, Glossner 2016).
Liability issues
In addition to the possible violation of proprietary rights,
the issue of product liability for the market with additively
manufactured products has not yet been clearly resolved.
Product liability law provides for possible claims against
the manufacturer or seller with regard to faulty parts or
components. Due to the fact that additive manufacturing
allows the production of products in a private context
based on 3D CAD data, this gives rise to new liability issues.
The current jurisprudence assumes that the producer is
liable for damages to legal assets which result from an
incorrectly manufactured product. Whereas the Federal
Supreme Court emphasises the producer liability as a
result of a behaviour-related error, European product
liability law does not focus on the incorrect behaviour of
a company when assessing the liability issue but rather
the product fault as such.

In view of the fact that the design, fabrication and assembly
take place virtually in additive manufacturing, and are often
carried out at different locations and by different people
and companies, the “special aspects of the division of
labour in production are particularly visible” (VDI: Status-
report “Additive Fertigungsverfahren”, Verein Deutscher
Ingenieure e.V., September 2014). One can assume that
within the context of industrial manufacturing, the final
manufacturer will be liable for product errors with a view
toward the design responsibility and liability claims will
arise within the internal relationships in the case of faulty
designs. However, differences arise within the context of
additive manufacturing when the manufacturing is carried
out for a private individual as the end consumer. In this
case, the final manufacturer can be made comprehensively
liable for the errors of an additively generated product.
The lawyer Dr. Markus Bagh advises companies who are
intending to do business creating 3D prints to include
an ‘exclusion of liability for print on demand’ clause in
their terms and conditions (Horsch, Florian: 3D-Druck
für alle – Der Do-it-yourself-guide. Munich, Vienna: Carl
Hanser Verlag, 2014).
It remains unclear whether the jurisprudence with regard
to the situation as to whether a private individual can
become the manufacturer within the context of product
liability law by operating his own additive manufacturing
system. According to paragraph 4 of the Product Liability
Act, the manufacturer of a product is the party “which
has manufactured the end product, a basic material or a
sub-product”. Given that the legislative authority always
uses the product term as per paragraph 2 of the Product
Liability Act together with the manufacturer term, lawyers
doubt whether a liable independent action on the part of
a private individual can actually occur in the case of the
private creation of a product with the help of an additive
manufacturing system on the basis of finished design data.
If the data is not independently modified, then printing
a component can also be regarded as a pure assembly
activity in accordance with the manufacturer’s specifica-
tions. As a result, the designer would then be responsible
(VDI: Statusreport “Additive Fertigungsverfahren”, Verein
Deutscher Ingenieure e.V., September 2014).
A clear judgement has not yet been reached regarding
liability in the context of consequential damages – where
an additively manufactured component causes damage
to the machine in which it is constructed – and the effect
this then has on warranty, guarantee or compensation
for damages.
Data protection law
The data protection law is based on the legal concept
of the general right to privacy, according to which, each
person may decide for themselves with whom, when and
which of their personal data they wish to make accessible.
The GDPR forms a uniform legal framework at a European
level for the processing of personal data. This affects every
process where information is handled which relates to
an identified or identifiable natural person. Risks of vio-
lating data protection law essentially occur when data is
unlawfully collected, not deleted after the corresponding
time has elapsed, lost or accidentally passed on to third
parties, or when incorrect data is processed, as well as
data theft. As such, each company must analyse their
individual structures and processes to identify the data
affected by the data protection law and to take precautions
to avoid these risks.
As regards the additive manufacture of products, the
scope of the data protection regulations substantially
depends on how and to what extent personal data is pro-
cessed. The extent to which a company is even affected
by it differs according to sector and production-specific
characteristics. In biomedical technology in particular,
personal data - which includes sensitive health data, for
example when 3D printing dental prostheses - is pro-
cessed. In the lifestyle and food industry, personal data
can be present well into the production process, while
in additive manufacturing for the automotive, tool and
mechanical engineering industries, the processing of
personal data tends to be limited to ordering processes
or account settlements. Where there tend to be business
relationships only between companies, the character of
data processing is different from transactions with private
persons, for example in manufacturing personalised
glasses or shoes.
An information leaflet (2018)
offers more in-depth infor-
mation on these issues ar-
ranged by theme and the
corresponding support
materials on which meas-
ures could be necessary to
comply with data protec-
tion regulations. (Available
in German only)
61
 4.  ADDITIVE MANUFACTURING:
SELECTED SUCCESS STORIES,
POTENTIALS AND PROJECTS FROM HESSEN

62
4.1 MITTELHESSEN UNIVERSITY OF APPLIED SCIENCES:
AddiFeE additive manufacturing of metal components for mechanical and automotive engineering . . . . . . . . . . . . . 64

4.2 KEGELMANN TECHNIK GMBH:

AutoAdd – Automation of the process chain for customer-specific additive production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.3 EDAG ENGINEERING GMBH:

Additively manufactured lightweight structure and weight-reduced bonnet hinge with
pedestrian protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.4 HERAEUS ADDITIVE MANUFACTURING:

Sophisticated metal powder for additive production in the aerospace or automotive sectors . . . . . . . . . . . . . . . . . . . . . . . . 68

4.5 FKM SINTERTECHNIK GMBH:

Factory of the future for the age of additive manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.6 SAUER PRODUCT GMBH:

Faster introduction to market thanks to additive manufacturing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.7 IETEC ORTHOPÄDISCHE EINLAGEN GMBH PRODUKTIONS KG:

Tailor-made insoles for diabetes patients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.8 PHILIPPS-UNIVERSITÄT MARBURG:

Additive manufacturing of individual dental prostheses and jawbones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.9 TECHNISCHE UNIVERSITÄT DARMSTADT:

Individual mass production of medical products .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.10 FRAUNHOFER LBF:

Polymerisable printing ink for low porous 3D printing and Piezo actuators with SLM casing . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.11 HOCHSCHULE FÜR GESTALTUNG OFFENBACH:

Projects related to additive technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.12 FRAME ONE:

Customising bicycles using additive production .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.13 UNIVERSITÄT KASSEL:

3D printed cement-bound shaped parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.14 TATCRAFT GMBH:

The largest makerspace in the Rhine-Main area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.15 FRAUNHOFER IGD:

Voxel-based 3D printer driver Cuttlefish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.16 FIBERTHREE GMBH:

Using carbon fibres to create more efficient additive components .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.17 CONTINENTAL ENGINEERING SERVICES GMBH:

Additive Design and Manufacturing competence centre (ADaM) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

63
 4.1 MITTELHESSEN UNIVERSITY
OF APPLIED SCIENCES

A ddiFeE – Additive manufacturing of metal components for
mechanical and automotive engineering
Laser beam melting has been used for the additive pro-
duction of metal components in the aerospace industry
as well as dentistry and biomedical technology for some
years. There is still a vast array of applications for the
technology to be discovered in mechanical engineering
and in the automotive industry. For this reason, we lack
essential knowledge of suitable production parameters. A
research project conducted at Mittelhessen University of
Applied Sciences from 2015 to 2017 addressed questions
about the manufacture of metal series components for
vehicle construction using additive production processes.
In the project, issues related to the optimum layer thickness,
positioning in the construction space and the track width
as well as the power density of the laser were clarified.
For decades, there have been known parameters for
the construction and assembly of a component made of
common materials such as rolled steel or die-cast alumin-
ium. In the project, scientists have now also been able
to determine reliable material parameters for additive
production. A particular highlight is the first determination
of cyclic material parameters (cyclic stress-strain curve
and Wöhler curve) for additively produced aluminium
for practical and theoretical use.
Determination of material parameters in the project AddiFeE
(Source: Mittelhessen University of Applied Sciences,
Photo: HA Hessen Agentur GmbH, Jan Michael Hosan)
“In the investigations, we were looking at mechanical
properties such as tensile strength, stiffness and elasticity,
resilience or porousness”, explains Professor Heinrich
Friederich. The partner consortium was able to deter-
mine parameter sets for additively produced aluminium
(AlSi10Mg) and additively produced tool steel (1.2709).
The team were able to basically establish the relationships
between production parameters and product properties,
which will have a positive effect on component quality in
the future, particularly with regard to safety relevant parts.
64

Using the example of several parts for vehicle air-con-
ditioning systems (compressors) which were additively
manufactured and tested as prototypes in the project,
the team were able to explicitly prove quality and prac-
ticability. This possibility can now also be used directly
for other companies and applications.
“We have summarised the results in concrete instructions
which describe how these components can be produced
with reliable and reproducible properties. These serve as
a means for the builders to construct components with
a high level of process safety and quality”, summarised
Professor Udo Jung from the Automotive, Mobility and
Material Research competence centre (AutoM for short).
In 2017, the specialist book “Additive Fertigung von
Bauteilen und Strukturen” [The Additive Manufacturing of
Components and Structures] (Springer Verlag, 2017) was
published and describes the essential results of the project
in the overview chapter “Rapid Prototyping in Machine
and Automotive Construction – Fatigue Characteristics
of Additively Produced Components”.
The research project at Mittelhessen University of Applied
Science lasted for two years with an overall cost of 415,000
euros. Partners of the university were FKM Sintertechnik
from Biedenkopf, Sanden International (Europe) based in
Bad Nauheim, Henkel Modellbau from Breidenstein and
the faculty of material mechanics at Technische Universität
Darmstadt. The state of Hessen supported the project
with 300,000 euros as part of the “Landes-Offensive zur
Entwicklung Wissenschaftlich-ökonomischer Exzellence
(LOEWE) [State Programme for the Development of
Scientific and Economic Excellence]
This project (HA project no.: 464/15-06) was supported
as part of the LOEWE - Landesoffensive zur Entwicklung
Wissenschaftlich-ökonomischer Exzellenz, funding line 3:
KMU-Verbundvorhaben..
i
Mittelhessen University of Applied Sciences
Prof. Dr.-Ing. Udo Jung (qualified engineer)
Kompetenzzentrum für Automotive, Mobilität und
Materialforschung (AutoM)
Am Dachspfad 10, 61169 Friedberg
Telephone: +49 6031 604 337
Email: udo.jung@autom.thm.de
www.m.thm.de
 4.2 KEGELMANN TECHNIK GMBH:

A utoAdd – Automation of the process chain
for customer-specific additive production
The project aim of AutoAdd covers the construction and
implementation of a digital, automated and continuous
process chain for customer-specific additive production.
AutoAdd was recommended for funding as part of the
LOEWE 3 support programme run by the state of Hes-
sen and started on 1 July 2016. The partner companies
Kegelmann Technik GmbH (Rodgau, Jügesheim) and :em
engineering methods AG (Darmstadt) are constructing
a digital, automated and continuous process chain for
customer-specific additive production as part of the
project, in collaboration with the Technische Universität
Darmstadt, Computer Integrated Design (DiK) faculty.
Reference projects of additive production, such as a vehicle
door (Source: Kegelmann Technik GmbH)
This demonstrates all processes from the receipt of the
customer orders, to the computer processing of the orders
and the pre-processing of CAD data, to preparation for
production, production itself, as well as post processing,
right up to the sale, supply, delivery and distribution of
the additively produced components. With AutoAdd,
the customer experiences a reduction in costs when
procuring additive components and the order processing
time is significantly shorter. The possibility of requesting
custom components is also made significantly easier for
the customer. The enormous market potential of additive
production and the increasing demand for customer-spe-
cific products is relevant to all known sectors. From aircraft
construction, to the automotive industry, to machine and
systems construction, right up to the consumer market,
all branches will benefit from this new kind of process
chain and order processing.
Typical, representative components were used to test
the overall developed system. In this way, the team were
able to ensure that a solution was developed that is ready
to market. After the successful development and testing
of the prototype software demonstrators, this is tested
in reality with customer orders. The aim is to adapt the
acquired solutions for more processes directly after the
end of the project in order to achieve a broad market
entry and to strengthen the Hessen location.
Removal of components from the construction space after
laser sintering (Source: Kegelmann Technik)
This project (HA project no.: 500/16-12) was supported
as part of the LOEWE - Landesoffensive zur Entwicklung
Wissenschaftlich-ökonomischer Exzellenz, funding line 3:
KMU-Verbundvorhaben.
i
Kegelmann Technik GmbH
Stephan Kegelmann, Managing Director
Gutenbergstraße 15, 63110 Rodgau-Jügesheim
Telephone: +49 6106 8507-10
Email: info@ktechnik.de
www.ktechnik.de
65
 4.3 EDAG ENGINEERING GMBH:
 dditively manufactured lightweight
A
structure and weight-reduced bonnet
hinge with pedestrian protection

The continual improvement of lightweight construction

of vehicles is one of the strategically relevant topics in the
automotive industry. Ambitious weight targets and the
market introduction of a whole range of electric cars in
the coming years represent current drivers for lightweight
construction. In recent years, Wiesbaden engineering
specialist EDAG was able to expand its engineering com-
petence in additive manufacturing with the development
of additively manufactured vehicle chassis such as the
studies Genesis and Light Cocoon.

Additively manufactured lightweight

bonnet hinge LightHinge+
(Source: EDAG Engineering GmbH)

In 2017, EDAG continued with the development of an

ultralight space-frame concept as a technology platform
by using additive manufacturing methods. At the IAA 2017
in Frankfurt, the “NextGenSpaceframe 2.0” was presented
as an intelligent modular system with bionically designed
and additively manufactured joints in combination with
extruded profiles. The concept is produced in an extremely
flexible manner to be able to also depict the increasing
number of vehicle derivatives with a focus on economy. It
was constructed completely out of the material aluminium
and has an additional savings potential in terms of weight.

NextGenSpaceframe 2.0: Additively manufactured

joints in combination with extruded profiles
(Source: EDAG Engineering GmbH)

66
EDAG Light Cocoon study (Design: EDAG Engineering GmbH)
The lightweight structure was produced with few tools
and on demand, and developed by EDAG together with
Constellium (Singen), Siemens PLM Software (Cologne),
Laser Zentrum Nord (Hamburg) and Concept Laser (Licht-
enfels) as well as the associated partners of BLM Group
(Levico, Italy), KW Automotive (Fichtenberg) and 3M
(Neuss). Here, software for the continuous engineering
of the additively manufactured chassis joints and alumin-
ium extruded profiles was used for the first time in the
development stage.
Laser beam welding or adhesive bonding, for example, can
be used to combine the additively manufactured chassis
joints with the aluminium profiles using multi-chamber
technology. For the former, various materials are possible.
In trials and calculations for the longitudinal beam area,
it could be proven exemplarily that the crash areas of
the “Spaceframe” absorb energy in a controlled manner
and the joints do not fail structurally. In the continuing
development, the production costs were further reduced
by minimising the support structures within the joints. The
continuous engineering data process chain contributed
to the achievement of significantly better performance
in development as well as in production. Compared to
traditional vehicle lightweight structures available on
the market, the weight could be reduced by a further
20 percent for high-end vehicles and super-sports cars.
In a further project, EDAG developed a lightweight bonnet
hinge with integrated passenger protection with its part-
ners under the name of “LightHinge+” and also achieved
an enormous saving in weight of 50 percent compared
to the reference thanks to the use of additive production
technologies. The hinge was produced in collaboration
with “voestalpine Additive Manufacturing” (Düsseldorf)
and with “Simufact Engineering” (Hamburg).
Thanks to the use of topology optimisation and bionic
construction principles, the team succeeded in working
out the minimum material requirement. The lightweight
structure was then further developed in such a way that
during production using laser beam melting on part of
voestalpine, very little support structure was required,
and thus only minimal reworking. In addition, the produc-
tion-specific thermal distortion of the component could
also be compensated with a reforming of the geometry,
thanks to the use of simulation software.
The integration of the active hinge function represents
a particular feature of the “LightHinge+”. If a pedestrian
collides with the vehicle, a pyrotechnic actuator is triggered
which impacts with a defined area of the hinge. At this
point, complex break structures have been integrated
in a monolithic fashion which release an additional joint
when external force is exerted and as a consequence, the
motor hinge can be elevated. The impact of the pedestrian
is therefore absorbed by the free space which has been
created. The “LightHinge+” combines safety, lightweight
construction and production-ready design.
i
EDAG Engineering GmbH
Dr. Martin Hillebrecht
Head of CC Lightweight Construction, Materials &
Technology
Reesbergstraße 1, 36039 Fulda
Telephone: +49 661 6000-610
Email: info@edag.de
www.edag.de
67
 4.4 HERAEUS ADDITIVE MANUFACTURING:

S ophisticated metal powder for
additive production in the aerospace
or automotive sectors

3D printed steering shaft bracket for student racing

cars features 50 percent weight reduction

Five ultralight 3D printed components from Heraeus fea-

ture in the new Technische Universität Darmstadt racing Additively manufactured
car for the race series Formula Student 2017. A steering steering shaft bracket
shaft bracket from the aluminium alloy AlSi10Mg is almost (Source: Heraeus)
50 percent lighter than its predecessor. The steering shaft
bracket by Heraeus, designed precisely according to the
racing team’s requirements and produced using additive
production methods, weighs just under 300 grams with
the mechanical strength and stability remaining the same.
“We completely reconstructed the component and opti-
mised it again and again using simulations to achieve the
maximum weight reduction possible. The combination of
material competence, construction expertise and printing
know-how was crucial for us achieving this ambitious goal”,
explains Tobias Caspari, head of additive manufacturing
at Heraeus. A total of four motor shafts were also printed
for each wheel suspension on the new Technische Uni-
versität Darmstadt racing car, which are also around 50
percent lighter than the former models.

Five ultralight 3D printed components from Heraeus feature in

the new Technische Universität Darmstadt racing car for the
current Formula Student race series (Source: Heraeus)

Since 2015, the Hanau technology company has been

developing sophisticated metal powders and the related
processes for 3D printing. Their portfolio also includes
amorphous metals (metallic glasses), precious metals
(gold, silver and platinum alloys), high-melting refractory
metals such as molybdenum, niobium or tantalum, the
most varied of metal alloys as well as bioresorbable ma-
terials and gradient materials. The provision of refractory
metal powders for additive manufacturing in particular is
completely new ground for metal printing technology,
because these materials require such high temperatures
(up to 2,500°C) that purely from a physical perspective,
only a few companies can even work with them. Heraeus
develops, supplies and tests the right powder for the
layered construction of components for industrial man-
ufacture. Metal and process knowledge are therefore
crucial, because the metal powder and printing process
must be perfectly matched.

Heraeus develops, supplies and tests the right powder

for additive manufacture (Source: Heraeus)
68
The 3i print project shows the full potential of industrial 3D
printing for the automotive industry with the front bonnet
structure of an old VW Caddy
(Source: csi entwicklungstechnik)

Heraeus also makes it possible to create complex shapes
from amorphous metals. This innovative material class,
also known as the metallic glasses, is suitable for an
unusual number of high-tech applications. Amorphous
metals are shock-absorbing, scratch-resistant and also
have many other good suspension properties - inter-
esting, for example, when it comes to membranes for
injection nozzles, casings for entertainment electronics
or as loudspeaker caps.
“3D printing will be the choice for many areas of technology
in the future. In the aerospace or automotive industries,
additive manufacturing makes savings in weight possible
which can no longer be achieved using classic shapes.
Much lighter and yet, more stable functional parts can
be produced with completely new design possibilities.
At the same time, we save resources and can recycle any
excess powder”, says Caspari.
Race series “Formula Student”
The race series “Formula Student” is an international
construction competition where teams of students from
all over the world compete against each other with racing
cars they have designed and built themselves. First known
as Formula SAE 1981 in the USA, the race series came
to Europe in 1998 as Formula Student. The Technische
Universität Darmstadt has founded an association to
compete in Formula Student: The TU Darmstadt Racing
Team e.V. (DART). It is both recognised as charitable
organisation as well as a university group at Technische
Universität Darmstadt.

The diversity of applications ranges from weight-reduced

bearing plates for the Formula Student racing cars addi-
tively produced from curable aluminium casting alloys
right up to the resource-saving production of control
nozzles made from platinum alloys for satellites. The
current Heraeus collaborations include the 3i print pro-
ject, where the example of the front-end structure of an
old VW Caddy shows the full potential of industrial 3D
printing for the automotive industry. In a further project
with the company Moog, hydraulic control blocks are
additively produced for robot applications (for example,
salvage robots). Heraeus supplied and tested the technical
high-strength aluminium alloy Scalmalloy® to produce
the components. Using the example of a hydraulics
application, it was also shown how additive production
of metal sets out towards economic industrialisation and
series production. As part of a joint project, a hydraulic
servo-valve was optimised by Bosch Rexroth, specialist
for drive and control technology. Aside from Heraeus,
powder specialists with comprehensive material knowl-
edge, the partners also included systems manufacturer
Trumpf with their industrialisation competence.
i

Heraeus Holding GmbH

Tobias Caspari
Head of Additive Manufacturing at Heraeus
Heraeusstraße 12-14, 63450 Hanau
Telephone: +49 6181 35-0
Email: pr@heraeus.com
www.heraeus.com

69
 4.5 FKM SINTERTECHNIK GMBH:

Factory of the future for the age
of additive manufacturing
FKM Sintertechnik has been active as a laser sintering
provider for more than 20 years. The company has long
regarded laser sintering as a fully viable production pro-
cess extending beyond prototype construction. When
the company opened its new plant in Biedenkopf near
Marburg in July 2014, it put into operation a complete
manufacturing facility with laser sintering systems, bring-
ing additive manufacturing up to the level of industrial
production. The unique aspect: The new production
facility is designed consistently to industrial standards
while taking into consideration demanding environmental
principles. The energy requirements, for example, are
met using green electricity. Furthermore, the consistent
recuperation of heat energy from the production process
allows the factory to function without a heating system.
The energy recuperated is sufficient to heat both the
warm process water and the building itself down to an
external temperature of -15 degrees Celsius.
New laser factory in Biedenkopf (Source: FKM Sintertechnik GmbH)
70
The centre of the facility is a manufacturing hall with ap-
proximately 3,700 square metres and 39 laser sintering
systems for manufacturing finished plastic and metal
components. The facilities are primarily supplied with pow-
dered material via a fully automatic system consisting of a
closed-circuit with multiple silos and a central distribution
station. All of the upstream and downstream processing
activities are carried out in a process-optimised infrastruc-
ture. A flexible production control system manages and
monitors all of the processes from the quality-control of
the delivered powder material to the quality assurance of
the finished sintered parts. “This enables us to guarantee
the optimal use of the systems and the customers profit
from shorter lead and delivery times,” explains Jürgen
Blöcher, Managing Partner of FKM Sintertechnik.
Production hall with 39 laser sintering systems and automated control of the material circuits (Source: FKM Sintertechnik GmbH)

A variety of different materials can be used for the manu-

facturing process, depending on the customers’ individual
requirements. Polyamides such as PA 11 and PA 12, the
flexible elastomer TPU (thermoplastic polyurethane) with
its rubber-like properties or the chemical and heat-re-
sistant polyetheretherketone PEEK HP3 can be used as
plastics. The metals include tool steel, stainless steel and
aluminium, along with cobalt-chrome, for example, for
dental applications, and Inconel 718, a nickel-chrome
alloy which is resistant to extreme environments and used
for high-temperature applications such as turbochargers
or turbine blades.

A current example for the use of additive manufacturing

in small-series production, individualisation and spare
parts is the multi-part storage compartment for monetary
notes which are integrated into the side panel on the left
side of the drivers’ seat on Mercedes Benz city buses.
This complex component consists of a casing with insert
compartments and a lid. Hinges, assembly clips and a
handle are integrated. It is manufactured in “one piece”
in an additive manner using a laser sintering process. The
surface is then smoothed and given an anthracite colour.
This means that the component meets the prescribed
production standards, comparable to traditional produc-
tion processes. In conventional construction practices, it Additively produced component for a storage compartment
would have been necessary to produce the individual from polyamide (Source: FKM Sintertechnik GmbH)
parts with several expensive plastic injection moulding
tools and then assembling the individual parts.

The cost advantages arise from the elimination of the need

of special tools in the production processes, as well as
no longer having to keep the necessary stock. Individual
components and spare parts can be produced in precisely
the desired amount in a quick and economical manner.

FKM Sintertechnik GmbH

Jürgen Blöcher
Managing Director
Zum Musbach 6, 35216 Biedenkopf
Telephone: +49 6461 75852-10
Email: info@fkm-sintertechnik.de
www.fkm-lasersintering.de

71
 4.6 SAUER PRODUCT GMBH:


Faster introduction to market thanks to
additive manufacturing 

sauer product, a company from Dieburg in southern Hes-

sen, is an additive manufacturing pioneer for prototypes
and has been using the technology since 1988. Over
the course of time, more and more new technologies
have arisen in combination with new materials. In order
to offer optimum solutions for specific applications, the
company provides a broad spectrum of prototyping
technologies. The product portfolio includes both con-
ventional processes as well as innovative technologies
such as laser sintering.

As a result of the company’s extensive experience, sauer

product is now capable of manufacturing even those
workpieces with extremely complex geometries rapidly,
at affordable prices and with the precision required for
the application. The company is one of the pilot users and
has already been utilising SLM processes for ten years. It
has gained in depth experience and now numbers among
this technology’s leading providers.
sauer product offers materials including stainless steel,
hot-working steel and cobalt-chromium steel, along
with aluminium and titanium. As such, the company
offers a broad range of metallic materials for additive
manufacturing.
Additive manufacturing procedures have proven highly
successful for prototype construction. One outstanding
example is the “Carrier and covering panel for a vacu-
um cleaner” project carried out by sauer product. This
seemingly simple component required a prototype for
stress and functional testing. However, if using conven-
tional methods, this prototype can only be manufactured
using an expensive, multi-stage forming and punching
tool. The SLM process utilised by sauer product is en-
tirely different: Based on the 3D CAD volume model, the
production process was programmed in just one hour,
while the approximately 90 x 230-millimetre carrier panel
was manufactured in twelve hours by the fully automatic
system. Thus, the user received the finished prototype for
testing only one week after placing the order.
Metallic 3D print of a structural component
(Source: sauer product GmbH)
In fact, the significant time savings that sauer product was
able to offer were more valuable than the savings in tool
costs for manufacturing the prototype. The manufacturing
of the conventional tools alone otherwise would have taken
approximately four weeks. Thanks to additive manufactur-
ing using SLM processes and sauer product’s expertise,
the customer was able to reduce the originally planned
time to market by approximately 15 percent. The critical
factor was that the additively manufactured workpieces
possessed the same mechanical characteristics as the
conventionally processed original material.
sauer product also creates benefits when it comes to
specially designed unique systems such as those for
power stations. These components are often subject to
highly specific requirements. In view of this, the SLM pro-
cess often proves to be the prevailing method for series
production given that the “series” in this case consists of
small quantities.

sauer product GmbH

Stephan Sperling
Frankfurter Straße 73, 64807 Dieburg
Telephone: +49 6071 2070-170
Email: ssperling@sauerproduct.com
www.sauerproduct.com

72
 4.7 IETEC ORTHOPÄDISCHE EINLAGEN GMBH:
PRODUKTIONS KG

Tailor-made insoles for diabetes patients
Diabetes patients often experience atrophy of the nerve
endings in their feet. The affected patients then no longer
feel painful spots, which can lead to pressure points and
the formation of sores. Insoles which are very soft at the
injured area and which are hand-made and customised
from various materials by orthopaedic shoe technicians
promise relief. The unique character of the insoles means
that the desired success has barely been proven scientifi-
cally. As such, health insurance providers in particular are
interested in digitising the insole process and in doing so,
making them accessible for the scientific collection of data.
In the BMBF project “LAUF” (Lasergestützter Aufbau von
kundenindividueller Fußbekleidung, or creation of custom
footwear using lasers), scientists at the Fraunhofer-Institute
for Mechanics of Materials IWM and for Environmental,
Safety, and Energy Technology UMSICHT work together
with industry partners in material development and digiti-
sation. A software package was developed which is used
by orthopaedic shoe technicians to design the soles for
each individual patient and print them on their own 3D
printer. This in turn brings about even more benefits: on
one hand, as desired by the health insurance companies,
you can see which mechanical properties each insole has.
On the other hand, the insoles will be produced more
affordably in the future.
3D structures made from TPU for insoles. The structures were
created using CAD, their properties simulated and compared
using experiments (Source: Fraunhofer IWM)
By using a combination of various structures in an insole,
the hardness required in specific places can be set digitally
(Source: Fraunhofer IWM)
The foundations for 3D printing the soles were laid a few
years ago by industry partners Covestro and Lehman-
n&Voss&Co. They first developed an elastic material for
selective laser sintering (SLS) using thermoplastic poly-
urethane (TPU). This was very well suited to orthopaedic
insoles. Together with material experts from Fraunhofer
UMSICHT, further types of plastic powder were developed
to make the insoles more applicable for the orthopaedic
sector.
Scientists at Fraunhofer IWM are optimising the 3D struc-
tures that this plastic should form in the insole. The mate-
rial itself does not determine how hard or soft the insole
will be; the shape also plays a role here. Using applica-
tion-oriented stress simulations, the team can investigate
which structures are required at each point to achieve the
desired properties. The data for the various insoles are
passed on to industry partners rpm GmbH and Sintermask
who print them using SLS systems. The partner Explius
is responsible for the 3D data processing. At the end of
the project, the software is available for orthopaedics
technicians at IETEC Orthopädische Einlagen GmbH.
IETEC Orthopädische Einlagen GmbH Produktions KG
Jürgen Stumpf, Managing Director
Am Frankengrund 3, 36093 Künzell
Telephone: +49 661 380070
Email: info@ietec.de
www.ietec.de
73
 4.8 PHILIPPS-UNIVERSITÄT MARBURG:

A dditive manufacturing of individual dental prostheses 
and jawbones

Given the individual nature of dental prostheses and the

individual pieces required, additive processes have devel-
oped into a viable alternative to traditional manufacturing
methods. Additive processes have also become increas-
ingly important when replacing jawbones, compensating
for tissue atrophy (known as resorption processes) which
occurs after tooth loss or with tissue that has to be removed
as a consequence of accidents or tumours. Replacing
missing teeth through tooth implants has now become
a routine activity in modern dental medicine. However,
due to the resorptive processes following tooth loss, the
jawbone volume often needs to be restored first before
the dental prosthesis can be implanted. The areas of the
jawbone requiring restoration are even more extensive
in the case of cancer. The jawbone is generally restored 3D printed bone scaffold for tissue engineering
by removing bone material from another part of the segmental lower jaw bone defects
body (such as the fibula) and applying it to the jawbone. (Source: Philipps University of Marburg)
However, this treatment method frequently results in
complications with the jawbone and also at the site where
the bone material has been removed. Professor Knabe-Ducheyne has been pursuing this goal
for over 25 years. The process is currently being tested on
At the Philipps Universität Marburg, dental specialist animals as part of an endowed professorship financed by
Prof. Christine Knabe-Ducheyne has been researching the Hanau company Heraeus-Kulzer with one million euros.
new bioceramics for additive manufacturing since 2011. Scaffolds containing blood vessels are implanted in the
These are intended for restoring collapsed jawbones femur, the tissue growth is examined and the resorption
and stimulating the growth of the body’s own bone characteristics of the bioceramic tested. “In the series of
before disappearing naturally after a period of three to tests, we are examining a variety of different scaffolds
six months. In a series of tests carried out on sheep, she in order to optimise the materials and conditions. We
successfully demonstrated the bioactivity of calcium alkali then want to carry out large animal tests with the best
orthophosphate as a replacement material. A current scaffold,” states Christine Knabe-Ducheyne, describing
research project is investigating manufacturing bone the research project’s approach. “It would be wonderful
material by means of tissue engineering with additive if I could spare patients the unpleasant bone removal
manufacturing processes. The geometry of the jawbone is process in the future.” (Source: Marburg Uni Journal no.
first scanned by means of computed tomography and the 44, Summer/Autumn 2014, ISSN 1616-1807)
required bone structure generated three-dimensionally.
The structure is then printed using a bioceramic material.
The so called scaffold can then be enriched with bone cells
and growth hormones and may also contain microscopic
blood vessels. When attached to the jawbone, the scaf-
fold then stimulates the bone growth and should merge
with the natural tissues before disappearing after a few
months. The implant can be fitted after this procedure.

Philipps-Universität Marburg
Prof. Dr. Christine Knabe-Ducheyne, DDS, PhD
Georg-Voigt-Straße 3, 35039 Marburg
Telephone: +49 6421 5863600
Email: knabec@med.uni-marburg.de
www.med.uni-marburg.de

74
 4.9 TECHNISCHE UNIVERSITÄT DARMSTADT:

I ndividual mass production of medical products

Biomedical technology is recording a rapid transformation

in all areas. The change in demographic, new medical
materials, increasing cost pressure and the demand for
customer-specific biomedical products are the main chal-
lenges for the future. In dental technology in particular,
these trends will lead to a significant change of today’s
processes over the next few years. The production tech-
nologies used must be able to keep up with development
and make efficient methods for the development of new
and adapted products and production systems available
for medical customers. The current multi-levelled and
long-term treatments are characterised by recursive
processes in dental laboratories.

The aim of the COMMANDD research project (COMputer

MANufactured and Designed Dental Products) was the
development of a dental design environment to simulta-
neously develop the product and the production system.
The new system allows the doctor or dental technician to
use a method to develop a high-quality individual denture
for the patient at a faster rate and with lower parts costs.
By using ablative and additive manufacturing processes
and thanks to significant changes of the overall digital
process chain, a software development environment was
created for medical specialists who are not trained in Additively manufactured SLM semi-finished product (1) and
technology which makes a “one-button” system available milled reworked SLM semi-finished product for comparison (2)
for all products. (Source: Technische Universität Darmstadt)

The development and prototypical implementation of a

data management system (FDDM) has allowed a reduc-
tion of the number of process stages in manufacturing
dentures from 12 to 6. The meaningful linking of coating
processes (SLM) with ablative processes (milling) contrib-
utes to the more economical manufacturing of dentures.
This was achieved by optimising the CAM system as well
as transferring the position location of the component
from the machine with the coating process to the milling
machine. The findings are not just relevant to dentistry, but
can also be transferred to the decentralised production
of custom patient endoprostheses. It is also possible to
use these findings in other industrial areas such as gen-
eral mechanical engineering or in turbine production. In
particular, the weight reduction demands in connection
with flow surfaces with less roughness offer great market i
potential. The project results were made available to
dental specialists at Technische Universität Darmstadt Technische Universität Darmstadt
by means of a process chain demonstrator. Institute for Production Management, Technology and
Machine Tools (PTW)
Prof. Dr. Ing. Eberhard Abele (qualified engineer)
Otto-Berndt-Straße 2, 64287 Darmstadt
Telephone: +49 6151 16-2156
Email: abele@ptw.tu-darmstadt.de
www.ptw.tu-darmstadt.de

75
 4.10 FRAUNHOFER LBF:

Polymerisable printing ink for low porous 3D printing and
Piezo actuators with SLM casing

A number of projects at the Fraunhofer Institute for Struc-

tural Durability and System Reliability (LBF) focus on the
advancement of additive manufacturing technologies or
their application within the context of direct product man-
ufacturing. As part of his dissertation in 2013, Christoph
Kottlorz described a project for developing polymerisable
inks and rapidly soluble powder for three-dimensional
printing. Despite the simple process, which is similar to
conventional 2D printing and the ability to simultaneously
utilise multiple printing jets, 3D printing is not yet being
used to its fullest potential for manufacturing of plastic
parts in small series. There are numerous reasons for this
and many arise from the porosity and low mechanical
strength of the components. That is why the goal of the
project was to develop new material systems for printing
low-porous bodies with significantly higher strength.

The project tested both new inks based on radically po-

lymerisable monomers along with the rapid, yet controlled
polymerisation with new powder mixtures. A two-com-
ponent initiator system was used for the polymerisation
of the monomer ink. The powder primarily consisted of
a soft elastomer and a small amount of hard polymethyl
methacrylate (PMMA). The best results were achieved with
HEMA (hydroxyethylmethacrylate) as the polymerisable
monomer. During 3D printing, the pores in the powder
were able to be filled with sufficient quantities of ink and
Piezo stack actuator which is housed in an SLM produced
the porosity was significantly reduced. As a result, the first
monolithic casing (Source: Fraunhofer LBF)
low-porous and mechanically stable test part geometries
with adequate translucency were successfully manufac-
tured using 3D printing. Practical testing determined a
similar strength and elasticity as attained by injection
moulding of comparable industrial polymers.

Another research area of the Fraunhofer LBF focuses

on developing adaptronic systems to enable advanced
methods of structural dynamics and signal processing
including the use of new forms of actuators and sensors.
Mass production processes such as injection moulding
have not been suitable for manufacturing durable housings
for piezo actuators. That is why scientists at the Fraunhofer
LBF have been working to use additive technologies. In
one project they have successfully tested the construction
of a monolithic housing for a piezo stack actuator manu-
factured by selective laser melting (SLM).

Individual production of sensors (Source: Fraunhofer LBF)

76
Tension test of fibres: 3D printed brackets with ultrasonic transducers (Source: Fraunhofer LBF)
In the SLM process, a laser beam heats metal powder to
its melting temperature, fusing the individual particles
together. This approach enabled the researchers from the
Fraunhofer Institute in collaboration with the Institute of
Production Management, Technology and Machine Tools
(PTW) at Technische Universität Darmstadt to generate a
sealed and durable housing and individually adapt the
characteristics to the corresponding task. The process
successfully eliminated the majority of the work for tool-
making and noticeably reduced the manufacturing costs
of the complex component produced in a small quan-
tity. The researchers selected a commercially available
piezo-ceramic stack actuator with the dimensions 7 x 7
x 32 millimetres and a maximum blocking force of two
kilonewtons with a maximum extension of 45 microns.
The greatest challenge consisted of integrating the piezo
actuator into the housing being produced during the
additive manufacturing process itself. The layer by layer
laser melting process was paused, the actuator inserted
and the process continued. At the same time, the heating
of the powder bed had to be taken into consideration.
The process temperatures ultimately had a positive effect.
The thermal contraction resulting from cooling served to
mechanically preload the actuator inside the housing,
which had a beneficial effect on the drive performance
without impairing the hermetic seal.
According to Professor Tobias Melz, the Head of the
Fraunhofer LBF, additive manufacturing processes enable
additional design options and, thus, optimised product
topologies. Print materials have been developed at the
Fraunhofer LBF which now enable similar strength and
elasticity to conventional injection moulding. In addition,
working together with the PTW department at Technische
Universität Darmstadt under the supervision of Professor
Abele, a process for additively manufacturing housed pi-
ezo stack actuators was patented, enabling a completely
new range of applications such as for vibration reduction
and energy harvesting.
i
Fraunhofer Institute for Structural Durability
and System Reliability (LBF)
Prof. Dr. Ing. Tobias Melz
(Head of the Institute, qualified engineer)
Bartningstraße 47, 64289 Darmstadt
Telephone: +49 6151 705-252
Email: info@lbf.fraunhofer.de
www.lbf.fraunhofer.de
77
 4.11 HOCHSCHULE FÜR GESTALTUNG
OFFENBACH:

Projects related to additive technologies
AudioView – orientation using sound
(Design: Frauke Taplik)
One example for the use of generative technologies in
biomedical technology is the earplug system AudioView,
developed by designer Frauke Taplik. This enables blind
people to acoustically locate objects marked by RFID. It
consists of a customised earbud generated with a 3D
Formetric 4D – 3D/4D spinal column and posture measurement
(Design: Stephan Brühl)
78

printer and a serial transmitter or speaker. The system
determines the position of obstacles in the room and
uses acoustic signals to indicate their location to the
blind person. The signals are only audible for the wearer
and simplify orientation. The shape of the earplugs has
been designed so that the auditory canals remain open.
Formetric 4D, a device for optically measuring the spinal
column for posture analysis, was developed in coop-
eration with Diers GmbH. A graphical striped pattern
developed by the optical company is projected onto
the patient’s back and is then recorded with a camera
system. Software calculates the position of the spinal
column and the hips using anatomical fixed points and
derives a three-dimensional model. This enables postural
defects to be diagnosed while the patient is standing,
along with the analysis of sequences of movements. The
mammoth stereolithography manufacturing technology
developed by Materialise was utilised to produce the
system. This is the first technology capable of additively
generating components with a length of more than two
metres. The additive manufacturing principle made it
possible to reduce the material requirements and wall
thickness to a minimum. A diamond-shaped internal
geometry analogous to the spinal column was used as
reinforcement, and is visible from the outside due to the
semi-transparent resin.
i
Hochschule für Gestaltung Offenbach
Office for Knowledge Transfer
Ulrike Grünewald
Schlossstraße 31, 63065 Offenbach am Main
Telephone: +49 69 800 59-166
www.hfg-offenbach.de/transfer
 4.12 FRAME ONE:

C ustomising bicycles using additive production
Crowded cities, too many cars, high volume of traffic,
environmental pollution: the topic of mobility does not
just face logistical challenges, but also ecological ones. An
answer to the problems of the age: switching to cycling.
However, traditional bicycles have never been arranged
according to the individual needs of the cyclist and are
mainly imported cheaply from abroad.
At the Hochschule für Gestaltung Offenbach, designers
Mervyn Bienek and Felix Pappe have developed a business
model for the regional provision of custom-made bicycles
in cooperation with economist Philip Hunold. Under the
brand name FRAME ONE, bikes are available at prices
equalling those of high-quality bikes off the shelf. The high
degree of customisation is made possible thanks to the
partially 3D printed bicycle frame. The frame is produced
locally and sustainable in the company’s own stores and
then assembled to form a complete two-wheeler.
The FRAME ONE frame consists of 3D printed nodal
points which are adapted individually to the cyclist and
standardised carbon tubes, which are assembled with
the nodal points into a frame, fork and handlebars. The
screw system means that all parts can be disassembled
and recycled separately. Mass production makes the
FRAME ONE – 3D printed bicycle frame
(Source: Mervyn Bienek, Felix Pappe, Philip Hunold,
Hochschule für Gestaltung, Offenbach am Main)
frame much simpler; the need for saddle supports and
handlebar stem is eliminated.
The bicycle is tailored to the cyclist to attain the best cy-
cling performance and allow an ergonomic, healthy cycle
without poor posture. FRAME ONE is customised by the
customer to match up with their aesthetic and functional
requirements. The additive production system means that
every desired position and frame type can be created.
Here, 3D printing is not just a production method, but
has become the new aesthetic of FRAME ONE.
The business model was awarded first place of the Hessen
Idee 2017 Founder’s Prize.
i
FRAME ONE
Mervyn Bienek
Bismarckstraße 10, 63065 Offenbach
Telephone: +49 157 54517715
Email: hello@frameone.bike
www.frameone.bike
79
 4.13 UNIVERSITÄT KASSEL:

3 D printed cement-bound shaped parts
In architecture, where large-scale and geometrically
complex components are often required in small batch
sizes, 3D printing technologies have remained largely
unexploited. Cement is a familiar material, and is also of
interest for this manufacturing technology given that it is
inexpensive and thus also suitable for large-scale parts.
As part of a research project initiated by the University of
Kassel and carried out together with industrial partners,
a process for additively manufacturing cement-bound
shaped parts was developed in 2012 and 2013. The via-
bility of the resulting products for the architectural field
and construction industry was also investigated as part
of a dissertation in the field of supporting structures and
solid construction.
In this process, a cement material is combined with addi-
tives and applied in layers in a construction space of up
to eight cubic metres using a system from voxeljet. The
mixture is also hardened selectively and in layers with an
aqueous solution. Processing a cement material using
3D printing represents a fundamental break from the
former processing methods given that the conventional
mechanical mixing to ensure an even mixture of liquid
and cement powder no longer takes place.
Investigations have shown that the physical properties of
the final product change considerably as a result. This is
due to anisotropies which occur as a result of the layered
structure and can be seen in the following scanning elec-
tron microscope picture.
Layered structure of a cement-bound material after
3D printing (Source: University of Kassel, A. Fromm)
80

In trials accompanying the development strength devia-
tions of up to 50 percent were found, depending on the
angle of incidence to the layer. These undesired effects
could be reduced through subsequent treatment, and
the overall strength increased simultaneously. When the
DIN EN 1992 standard is applied to such products for
exterior usage, then the relevant characteristics have not
yet been fulfilled. However, regardless of this, the goal
to manufacture a cement-bound shaped part using an
additive process which offers the designer the greatest
degree of design freedom could be achieved using the
3D printing process.
Further testing is required to utilise these new products
in the architectural field and construction industry due
to the fact that long-term studies found unexpected de-
terioration of the strength of the cement materials used.
Furthermore, strategies for permanently monitoring the
production process also have to be developed.
Prototype of a parametric module without formwork
(Source: University of Kassel, J. Frankenstein-Frambach, A. Fromm)
i
University of Kassel
Department of Civil Engineering
Prof. Dr. Ing. Ekkehard Fehling (qualified engineer)
Kurt-Wolters-Straße 3, 34109 Kassel
Telephone: +49 561 804-2608
Email: fehling@uni-kassel.de
www.uni-kassel.de/fb14bau
Note: still to be clarified
 4.14 TATCRAFT GMBH:

The largest MakerSpace in the Rhine-Main area
View of the Tatcraft MakerSpace workshops (Source: Tatcraft GmbH)
In June 2017 in a brick hall on the earlier premises of sys-
tems manufacturer Lurgi in the Seckbach industrial area,
the largest Makerspace in the Rhine-Main area celebrated
its opening under the name of “Tatcraft”. On around 1,500
square metres, designers, creative craftspeople, hobbyists
or furniture and interior designers are offered everything
they require to create their ideas and designs. As well
as a wood workshop, CNC mill, laser cutter and a water
jet cutting system to process glass, stone and metal, at
Tatcraft, the makers also have one of the world’s largest
industrial filament printers from BigRep in Berlin.
The two Tatcraft founders, Fabian Winopal and Tim
Fleischer, invested around half a million euros to make
a high-tech machine park available to young creatives
and small businesses. While membership of the Tatcraft
MakerSpace costs € 179 per month for an individual user,
students and apprentices pay a reduced amount of € 125.
Companies pay a higher amount for intensive use of the
machinery. Among other things, the business model is
to get companies in contact with young creatives. The
systems manufacturers see the Tatcraft MakerSpace as
a kind of showroom in the Frankfurt area. This is why the
start-up company was able to put together the machine
park on more favourable terms.
“The Rhine-Main area is the ideal place for our idea”,
says Fabian Winopal. “Many creatives and artists work
on exciting projects here. There is also a vast array of
colleges which specialise in design.”
MakerSpaces arose from so called Fablabs (“fabrication
laboratories”) which were brought into being by computer
scientist Neil Gershenfeld at the Massachusetts Institute
of Technology (MIT) in 2002. Gershenfeld wanted to
teach laypeople about how to handle digital production
technology such as 3D printing, CNC milling and laser
cutting, and bring the open-source idea to a wider pub-
lic. As at the Technische Universität Darmstadt, the first
Fablabs and Makerspaces were opened at colleges and
universities. We are now seeing a second generation of
professionally-driven, commercial facilities with equip-
ment used in particular by creatives from a professional
background. This development has become known above
all throughout the USA and China.
i
Tatcraft GmbH
Fabian Winopal (Managing Director)
Gwinnerstraße 42, 60388 Frankfurt am Main
Telephone: +49 176 8314 04 68
Email: corporate@tatcraft.de
www.tatcraft.de
81
 4.15 FRAUNHOFER IGD:

Voxel-based 3D printer driver Cuttlefish
With the ever-increasing importance of additive pro-
duction processes for the industry, the requirements of
functional scope and construction space of the systems
are also increasing. The desire for multi-material systems
and large-scale systems in particular can be recognised
on the market. This also significantly increases the control
software requirements. Above all, the accurate positioning
of materials to correctly replicate geometric and visual
characteristics presents a huge challenge due to the
immense volumes of data.
The Fraunhofer IGD is developing a streaming-ready,
Voxel-based printer driver to control multi-material 3D
printers under the name of “Cuttlefish”. Cuttlefish only
calculates the information required for the current print-
ing process, in order to minimise the necessary storage
space consumption and to be able to start the additive
manufacturing process within seconds, even for complex
and large 3D models.
Stratasys presented the GrabCAD Voxel Print solution for
its full-colour multi-material 3D printer J750 at formnext
2017 which opens up the system for use with third-party
software. The printer driver Cuttlefish by the Fraunhofer
IGD works seamlessly together with GrabCAD Voxel Print.
“The Fraunhofer IGD was one of the first users of our
GrabCAD Voxel Print solution, which allowed the institute
to develop Cuttlefish in such a way that the colour and
translucence capabilities of the full-colour Stratasys 3D
printer J750 could be fully utilised”, says Tomer Gallimidi
(Education Product Leader at Stratasys).
Cuttlefish creates complex models in 3D printing with highly
precise colour and translucence reproduction
(Source: Fraunhofer IGD)
82

The most recent version of Cuttlefish supports RGBA
textures which contain both colour and translucence
information and can range from completely opaque to
completely transparent. The driver allows users to print
several overlapping models, each with one or several
RGBA textures.
“3D models based on RGBA data are supported by 3D
file formats such as OBJ or WRL and can be generated
by many design and texturing tools”, Professor Philipp
Urban (Head of the 3D Printing Technology department
at the Fraunhofer IGD) explains the development. “RGBA
textures can also be generated or modified by popular
image processing programmes such as Adobe Photo-
shop. Cuttlefish closes the quality gap between virtual
design and its reproduction as a 3D printed model. We
now support Polyjetting, FDM, SLM and DLP printers and
can quickly connect new printing technologies thanks to
the modular workflow.”
These capabilities were demonstrated with a 3D anatomy
model consisting of 28 parts. Each of these was assigned
a different material which, all in all, were described by
425-megapixel colour textures. Transparent parts of the
model were simply generated by modifying the RGBA data.
.
Fraunhofer Institute for Computer Graphics Research
IGD
Prof. Philipp Urban
Head of Competence Center 3D Printing Technology
Fraunhoferstraße 5, 64283 Darmstadt
Telephone: +49 6151 155-250
Email: philipp.urban@igd.fraunhofer.de
www.igd.fraunhofer.de
www.cuttlefish.de
 4.16 FIBERTHREE GMBH:

U sing carbon fibres to create more efficient
additive components

Fibre-reinforced plastics are widespread in today’s tech-
nical applications. They mainly increase stability while
also reducing weight. In order to harness the benefits
associated with additive manufacturing for utilising the
known material advantages of injection moulding and
composite production, the founders of new Fiberthree
GmbH have specialised in the development and sale of
technical FFF filaments with fibre additives for processing
on standard market printers.
The focus of material development for FFF filaments is
currently on polyamides, as in many respects, these meet
the technical requirements of professional use in compo-
nents, allow good thermal and media resistance and do
not release any critical degradation products. During the
layered production process, anisotropic material values
prevail, yet the stabilities, even the structural stability in
the height axis, which is to say between the layers, is so
high that new possibilities of use are opening up.

Fibres cannot currently be incorporated into additive

multi-jet or powder bed processes. The melting or fused
layer modelling process with fibre-filled materials therefore
does not have an alternative if highly filled plastics are to
be used, and this requires less investment than the SLS
process, for example.
“We are a company which specialises in high-strength
components that can be produced quickly and affordably
without having to detour via special injection moulding
or composite structural shapes. We develop the material
and the components to be able to print it on machines.
Applications are mostly parts which should be mobile and
retain their high level of stability. The use of material at
the user end requires a professional environment for the
additive production process. If this proves too laborious,
we offer our expertise in engineering and job order pro-
duction. Our printer park is available for customers who
do not have a meaningful alternative in terms of cost.
Our customers value our quick execution”, Klaus Philipp
explains the Fiberthree GmbH business model.
Application example “additive orthesis production”
Ortheses are currently laminated by hand or produced
in series unit sizes. In a complex production process,
a light core, externally reinforced with carbon fibre
in a resin matrix, is normally milled. The 3D printed
component from carbon fibre reinforced polyamide
has an internal woven structure to save on weight. The
part takes 24 hours to print. The weight corresponds
to the laminated version at around 280 grams. The
orthesis can be adapted to the customer individu-
ally in CAD and is additively produced directly in a
production process.

Assembly aids or measurement gauges are examples

of applications which are particularly good for showing
the advantages of the material. These can be produced
completely flat and accurate in the 3D printer. The pro-
portion of fibre prevents distortion; for reinforced plastic,
fitting sockets or threaded inserts can be reworked after
printing. This means that a ready-to-use tool can be
produced directly from the CAD specification. When
compared to traditional metal cutting production with
aluminium, as well as the reduction in the material used,
the CNC processing stage is also substituted. The costs
savings result from the shortened process chain and the 3D printed drilling template (Source: Fiberthree GmbH)
lower expense of storing the materials. When companies
use their own printers, a saving of more than 50 percent i
is not a rare occurrence.
Fiberthree GmbH
Klaus Philipp (Managing Director)
Nieder-Ramstädter-Straße 22, 64283 Darmstadt
Telephone: +49 6151 734 75 900
Email: kontakt@fiberthree.de
www.fiberthree.com

83
 4.17 CONTINENTAL ENGINEERING
SERVICES GMBH:

A dditive Design and Manufacturing competence centre
(ADaM)
The market surrounding additive manufacturing process-
es has developed in a very positive manner over recent
years. In the near future, we expect the opening up of new
potential for using additive production methods, above
all in the automotive and electronics industries. Some of
the large supply industry companies are preparing for
this development and grouping their competences in AM
centres with a focus on the direct additive production of
small series, spare parts and prototypes.
Continental Additive Design and Manufacturing (ADaM)
(Source: Continental Engineering Services CES)
Continental Qualification Laboratory Karben (QL KRB)
(Source: Continental Automotive GmbH)
84
Additively produced pipe flange
(Source: Continental Engineering Services CES)
One of these competence centres in Hessen is ADaM
(Additive Design and Manufacturing) in the CES Product
Solutions technology park, owned by Continental Engi-
neering Services (CES) in Karben, near Frankfurt am Main.
Here, the worldwide Continental knowledge is gathered,
and all internal areas are made available. On an area of
560 square metres, a team of technicians and engineers
make use of a high-tech production workshop with all
current 3D printing processes. As well as high-tech ad-
ditive production, the CES Product Solutions technology
park also covers classic processes in mechanics, such as
metal cutting production or laser, bending, welding and
punching technologies, as well as injection moulding
and vacuum casting systems, and electronics production.
As a complete service provider, Continental Engineering
Services (CES) offer tailor-made development work for
automotive and industrial applications, but also the relat-
ed creation work: the production of prototypes, tool and
fixture construction as well as small series manufacture
and spare part production in one production location.
After over 40 years of experience, today more than 30,000
prototypes and samples are produced each year, as well as
around 20 small series. Customers are predominantly areas
within the company group and external companies from
the automotive industry. The demand for this expertise is
also increasing among customers from other industries.
In this way, a sports car manufacturer had them print a
brake calliper in an SLM process in Karben. The result: the
14-week prototype production time could be reduced to
seven days with the same material properties. As well as
tools, complex cooling elements are also in demand, for
example, which can be adapted to the surface they are
designed to cool, and can also dissipate heat effectively
through integrated cooling channels. The combination
of an assembly to form a single component such as
double-walled pipe flanges is also an application. In this Whether it’s a question of simple mechanical parts or
way, the reduction of welded flanges and walls saves on highly complex control devices, for example, the best,
weight and sustainable joining processes. most suitable production technologies are selected, or
well-combined with each other, for each project. The
corresponding plastic or metal materials are processed
for 3D printing, either by means of selective laser melting
(SLM), selective laser sintering (SLS), fused deposition
modelling (FDM) or stereolithography (SLA). Integration
into the CES Segments Product Solutions machine park
gives ADaM the ideal prerequisite to combine additive
manufacture with comprehensive technology advice,
reworking processes, classic production processes, du-
rability testing and validations.

With their qualifications laboratory at Continental’s group

site in Karben, there are modern facilities for the valida-
tion or assessment of parts available, from mechanical
function tests to environmental simulations to computer
tomography scans. Altogether, the material portfolio
for additive production is constantly being developed,
analysed and qualified. The product quality along the
entire value added chain is ensured thanks to certification
in accordance with the quality management standard for
the automotive industry IATF 16949.

Battery cooling with adapted cooling channels

(Source: Continental Engineering Services CES) i

Continental Engineering Services GmbH

CES Product Solutions
Stefan Kammann
Dieselstraße 6 - 20, 61184 Karben
Telephone: +49 6039 981 541
Email: stefan.kammann@conti-engineering.com
www.conti-engineering.com
 5. OVERVIEW
5.1 E SSIAN COMPANIES AND
RESEARCH INSTITUTIONS
apc-tec Process.Engineering
Alexander Petri
Backhausstraße 28a, 65555 Limburg
Telephone: +49 6431 529175
Email: info@apc-tec.de
www.apc-tec.de
Alesco Muster- Modell- und Prototypenbau GmbH
Rüdiger Irle
Justus-von-Liebig-Straße 40, 63128 Dietzenbach
Telephone: +49 6074 918 848 01
Email: info@alesco-gmbh.de
www.alesco-gmbh.de
B&S Zerspanungstechnik
Franz Jürgen Benz
Kleyerstraße 7, 64295 Darmstadt
Telephone: +49 6151 371 368
Email: info@schreiber-mechanik.de
www.schreiber-mechanik.de
C.F.K. CNC-Fertigungstechnik Kriftel GmbH
Uwe Wötzel
Gutenbergstraße 8, 65830 Kriftel/Taunus
Telephone: +49 6192 9945 0
Email: info@cfk-online.de
www.cfk-online.de
3D Systems
Deniz Okur (Marketing Manager)
Guerickeweg 9, 64291 Darmstadt
Telephone: + 49 6151 357 300
Email: info@3dsystems.com
www.3DSYSTEMS.com
4D Concepts GmbH
Alex Di Maglie (Managing Director)
Frankfurter Straße 74, 64521 Groß-Gerau
Telephone: +49 6152 92310
Email: mail@4dconcepts.de
www.4dconcepts.de
86
Competence Center Additive Design and
Manufacturing (ADaM)
Continental Engineering Services
Sascha Wörner
Dieselstraße 6-20, 61184 Karben
Telephone: +49 151 5267 8812
Email: sascha.woerner-ext@conti-engineering.com
www.conti-engineering.com
Conspir3D GmbH
Jan Giebels
Berliner Straße 1, 64354 Reinheim
Telephone: +49 6162 9167296
Email: info@conspir3d.com
www.conspir3d.com
DeguDent GmbH
Andreas Maier
Rodenbacher Chaussee 4, 63457 Hanau
Telephone: +49 6181 59-5800
Email: info.degudent-de@dentsply.com
www.dentsply.com
EDAG Engineering GmbH
Dr. Martin Hillebrecht (Head of CC Lightweight
Construction, Materials
& Technology)
Reesbergstraße 1, 36039 Fulda
Telephone: +49 661 6000-610
Email: info@edag.de
www.edag.de
Evonik Industries AG
Sylvia Monsheimer (PP-HP-GL-AT Director)
Paul-Baumann-Straße 1, 45772 Marl
Telephone: +49 2365 49-5911
Email: info@evonik.com
www.evonik.com
FabLab Darmstadt
Christoph Tauchert
Magdalenenstraße 4, 64289 Darmstadt, room 015
Telephone: +49 6151 16-24339
Email: kontakt@fablab.tu-darmstadt.de
www.fablab.tu-darmstadt.de
Fiberthree GmbH HP Deutschland GmbH
Klaus Philipp (Managing Director) Bastian Weimer (3D Printing Channel Manager)
Nieder-Ramstädter-Straße 22, 64283 Darmstadt Hewlett-Packard-Straße 1, 61352 Bad Homburg
Telephone: +49 6151 734 75 900 Telephone: +49 6172 26 888 05
Email: kontakt@fiberthree.de Email: bastian.weimer@hp.com
www.fiberthree.com www.hp.com

FKM Sintertechnik GmbH IETEC Orthopädische Einlagen GmbH Produktions KG

Jürgen Blöcher (Managing Director) Jürgen Stumpf (Managing Director)
Zum Musbach 6, 35216 Biedenkopf Am Frankengrund 3, 36093 Künzell
Telephone: +49 6461 9551-0 Telephone: +49 661 380070
Email: info@fkm-sintertechnik.de Email: info@ietec.de
www.fkm-lasersintering.de www.ietec.de

FRAME ONE invenio GmbH Engineering Services

Mervyn Bienek Eisenstraße 9, 65428 Rüsselsheim
Bismarckstraße 10, 63065 Offenbach Thomas Repp (Business Development Area Manager)
Telephone: +49 157 54517715 Telephone: +49 6142 899-266
Email: hello@frameone.bike Email: contact@invenio.net
www.frameone.bike www.invenio.net

Fraunhofer-Institut für Graphische Datenverarbeitung JM Kunststofftechnik GmbH

IGD Jürgen Merschroth (Managing Director)
Prof. Dr. Philipp Urban (Head of Competence Centre Akazienweg 25-27, 64665 Alsbach-Hähnlein
3D Printing Technology) Telephone: +49 6257 96997-0
Fraunhoferstraße 5, 64283 Darmstadt Email: info@jm-kunststofftechnik.de
Telephone: +49 6151 155-250 www.jmkunststofftechnik.de
Email: philipp.urban@igd.fraunhofer.de
www.igd.fraunhofer.de Kegelmann Technik GmbH
Stephan Kegelmann (Managing Director)
Fraunhofer-Institut für Betriebsfestigkeit und Gutenbergstraße 15, 63110 Rodgau-Jügesheim
Systemzuverlässigkeit LBF Telephone: +49 6106 8507-10
Prof. Dr.-Ing. Tobias Melz (Head of the Institute) Email: info@ktechnik.de
Bartningstraße 47, 64289 Darmstadt www.ktechnik.de
Telephone: +49 6151 705-252
Email: info@lbf.fraunhofer.de Makerspace Gießen MAGIE
www.lbf.fraunhofer.de flux – impulse: Seipel, Nils & Schmid, Johannes GbR
Georg-Philipp-Gail-Straße 5, 35394 Gießen
Heraeus Holding GmbH Email: info@flux-impulse.de
Tobias Caspari (Head of Heraeus Additive Manufacturing) flux-impulse.de/magie
Heraeusstraße 12-14, 63450 Hanau
Telephone: +49 6181 35-0 Makerspace Wiesbaden e.V.
Email: pr@heraeus.com Wandersmannstraße 60, 65205 Wiesbaden
www.heraeus.com Telephone: +49 152 292 260 92
Email: info@makerspacewi.de
Herbert Maschinenbau GmbH & Co. KG www.makerspacewi.de
Bernd Schmitt (Leiter Vertrieb)
Industriestraße 10, 36088 Hünfeld Matsuura Machinery GmbH
Telephone: +49 6652 609-0 Berta-Cramer-Ring 21, 65205 Wiesbaden-Delkenheim
Email: info@herbert.eu Telephone: +49 6122 78 030
www.herbert.eu Email: info@matsuura.de
www.matsuura.de
Hochschule für Gestaltung Offenbach
Office for the Transfer of Knowledge medacom GmbH
Ulrike Grünewald Olaf Gerlach
Schlossstraße 31, 63065 Offenbach am Main R.-Samesreuther-Str. 25, 35510 Butzbach
Telephone: +49 69 800 59-166 Telephone: +49 6033 74888-0
Email: transfer@hfg-offenbach.de Email: info@medacom.de
www.hfg-offenbach.de/transfer www.medacom.de

87
 O.R. Lasertechnologie GmbH
Dieselstraße 15, 64807 Dieburg
Telephone: +49 6071 209 890
Email: info@or-laser.com
www.or-laser.com
Perlon 3D Printing Filament
Ralf Hellinger
Hauptstrasse Nord 67, 69483 Wald-Michelbach
Telephone: +49 6207 9460
Email: info@perlon.com
www.perlon.com
Philipps-Universität Marburg
Prof. Dr. Christine Knabe-Ducheyne, DDS, PhD
Georg-Voigt-Straße 3, 35039 Marburg
Telephone: +49 6421 58636-00
Email: knabec@med.uni-marburg.de
www.med.uni-marburg.de
RKM – RotorKonzept Multikoptermanufaktur GmbH
Daniel Schmitt
Hauptstraße 113, 69518 Abtsteinach
Telephone: +49 6207 2033 533
Email: info@rotorkonzept.de
www.rotorkonzept.de
sauer product GmbH
Martin Sauer (Managing Director)
Frankfurter Straße 73, 64807 Dieburg
Telephone: +49 6071 2070-0
Email: info@sauerproduct.com
www.sauerproduct.com
Schmitt Ultraschalltechnik GmbH
Stephan Jeßberger
Albert-Schweitzer-Straße 6, 63165 Mühlheim
Telephone: +49 6108 793 441
Email: info@schmitt-ultraschall.de
www.schmitt-ultraschall.de
Tatcraft GmbH
Fabian Winopal (Managing Director)
Gwinnerstraße 42, 60388 Frankfurt am Main
Telephone: +49 176 8314 04 68
Email: corporate@tatcraft.de
www.tatcraft.de
Mittelhessen University of Applied Sciences
Faculty of Maschinenbau, Mechatronik und
Materialtechnologie/Mechanical engineering,
Mechanics and Material Technology
Prof. Dr.-Ing. Udo Jung
Am Dachspfad 10, 61169 Friedberg
Telephone: +49 6031 604 337
Email: udo.jung@m.thm.de
www.m.thm.de
88
Technische Universität Darmstadt
Faculty of Mechanical Engineering
Prof. Dr.-Ing. Reiner Anderl
Petersenstraße 30, 64287 Darmstadt
Telephone: +49 6151 16-6001
Email: anderl@dik.tu-darmstadt.de
www.dik.tu-darmstadt.de
Technische Universität Darmstadt
Institute for Production Management, Technology
and Machine Tools (PTW)
Prof. Dr.-Ing. Eberhard Abele
Otto-Berndt-Straße 2, 64287 Darmstadt
Telephone: +49 6151 16-2156
Email: abele@ptw.tu-darmstadt.de
www.ptw.tu-darmstadt.de
Technische Universität Darmstadt
Centre for Structural Materials
State Materials Testing Institute Darmstadt
Faculty and Institute for Materials Technology
Prof. Dr.-Ing. Matthias Oechsner
Telephone: +49 6151 16-24900
Email: oechsner@mpa-ifw.tu-darmstadt.de
www.mpa-ifw.tu-darmstadt.de
Trondesign creators + engineers
Achim Reitze
Johanna-Waescher-Str. 5, 34131 Kassel
Telephone: +49 0561 92 88 080
Email: info@trondesign.de
www.trondesign.de
Umicore AG & Co. KG
Andreas Brumby (Innovation Manager)
Rodenbacher Chaussee 4, 63457 Hanau
Telephone: +49 6181 59-4886
Email: info@eu.umicore.com
www.eu.umicore.com
University of Kassel
Faculty of Massivbau/Solid Construction
Prof. Dr.-Ing. Ekkehard Fehling
Kurt-Wolters-Straße 3, 34109 Kassel
Telephone: +49 561 804-2608
Email: fehling@uni-kassel.de
www.uni-kassel.de/fb14bau
University of Kassel
Institut für Werkstofftechnik / Metallische Werkstoffe
Prof. Dr.-Ing. Thomas Niendorf
Sophie-Henschel-Haus,
Mönchebergstraße 3, 34125 Kassel
Telephone: +49 561 804 7018
Email: niendorf@uni-kassel.de
www.uni-kassel.de
5.2 L ITERATURE
Abele, E.: Allocation and outlook of additive production
processes from a technical production view. Presentation
at the event “Additive Manufacturing” organised by the
Hessen Ministry for Economics, Energy, Transport and
Regional Development, Hanau, 23. September 2014.
Abele, E.; Anderl R.; Weiß P.: Computer aided Develop-
ment and Production of Dental Products. Aachen,
Shaker Verlag, 2015.
Anderson, C.: Makers. The Internet of Things: the next
industrial revolution. Munich, Vienna: Carl Hanser Verlag,
2013.
Anderl, R.: Additive Manufacturing or Generative Pro-
duction Processes – from Prototypes to Mass Production?
Presentation at the event “Additive Manufacturing“
organised by the Hessen Ministry for Economics, Energy,
Transport and Regional Development, Hanau,
23. September 2014.
Breuninger, J.; Becker, R.; Wolf, A.; Rommel, S.; Verl,
A.: Generative Production with Plastics: Design and
Construction for Selective Laser Sintering. Berlin,
Heidelberg: Springer Verlag, 2013.
Caviezel, C.; Grünwald, R.; Ehrenberg-Silies, S.; Kind, S.;
Jetzke, T.; Bovenschulte, M.: Additive Production Process-
es (3D Printing). Published by the Office of Technology
Assessment at the German Parliament. Work report no.
175, March 2017.
Fromm, Asko: 3D Printing Cement-Bonded Shaped Parts.
Fundaments, Development and Use. Kassel, Hessen:
Kassel University Press, 2014.
Frost & Sullivan 2016: Global Additive Manufacturing
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