Selective laser sintering (SLS) has established itself as a process for the cost-effective production of functional plastic components, particularly for medium to large quantities. While the actual printing process is increasingly standardized, downstream work steps such as de-powdering and surface treatment have often remained manual and less automated. This is precisely where the wiseON research project, funded by the Bavarian State Ministry of Economic Affairs, comes in: The aim is to use digitalization and automation to make the entire process chain from SLS production to finishing more efficient.
The project focuses on networking the individual production stages using standardized interfaces and a central IoT platform. Machine parameters, quality data and process times are recorded and analyzed in real time via OPC-UA and used to optimize the process steps. The inline recording of residual powder adhesions and the visual and gravimetric inspection of the finished parts are used for quality assurance and allow conclusions to be drawn about previous process parameters.
Another research focus is at Neue Materialien Bayreuth GmbH. Influencing factors such as powder reuse, component geometry and positioning in the installation space are investigated in a specially constructed SLS demonstration line. Combined measurement methods – such as particle size distribution and flowability – are used to document the influence on print quality and material properties. This allows recommendations for action to be derived for stable and cost-efficient series production.
The project shows that SLS processes can also be an economical alternative to injection moulding for batch sizes of up to 50,000 units – provided that the entire value chain is consistently digitalized and networked. The knowledge gained should significantly expand the industrial use of additive processes in the plastics sector in the medium to long term.
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