Fraunhofer IAPT showcases an end-to-end automated AM workflow at Formnext 2025

At Fraunhofer IAPT – Institute for Additive Production Technologies, the focus at Formnext 2025 (Hall 12.0, Booth D69) is on automation across the entire AM process chain. Centerpieces include collaborative robotics with a universal gripper, AI-assisted quality assurance using low-cost imaging, as well as processes for machining delicate structures and the in-situ post-processing of polymer parts. The goal is to reduce manual steps and achieve reproducible results in variant-rich small series.

For quality assurance, IAPT relies on a machine-vision solution that pairs simple cameras with AI evaluation. Instead of laboriously collecting real datasets, synthetic training data are generated to quickly provide models for metrology, defect detection, and part identification. According to the institute, this approach reduces costs and integration effort without impairing detection performance. Part handling is performed by a geometry-independent gripper that safely moves entire build platforms as well as complex or highly filigree geometries, enabling the flexible use of collaborative robots along the AM route.

In metallic applications, IAPT presents the additive reinforcement of a forged base structure to produce a Metal Leading Edge for protecting CFRP turbine blades. Material is deposited along the narrow edge using DED-LB/P. An eight-axis, synchronized toolpath with in-house process and path planning controls energy input, angle of incidence, and layer build-up so that the titanium alloy is applied precisely while leaving the sensitive structure undamaged. Based on IAPT’s experience, the hybrid process saves more than half of the titanium compared to purely conventional routes and reduces tool wear and rework.

For polymer printing, the institute is showing an in-situ surface-smoothing process that can be integrated into FDM systems. Post-processing is eliminated as a separate step, cutting overall processing times by up to 50 percent and enabling significant per-part cost effects. Overall, IAPT demonstrates how targeted automation and in-process quality assurance can make additive production more robust and economical.