The Fraunhofer Institute for Laser Technology ILT in Aachen has developed a method with which metallic components can be manufactured with localized pore structures using the LPBF (Laser Powder Bed Fusion) process. This makes it possible to produce dense and permeable zones within a single additive manufacturing step – without subsequent drilling, insertion of filters or complex component assembly.
The basis is an adapted LPBF process in which metal powder is applied in layers and selectively melted by laser. While classic applications are geared towards maximum density and mechanical stability, the controlled variation of the process parameters allows targeted pore formation.
“But if we allow porosity locally, for example, by changing the process parameters, we can create controlled permeability,” explains Andreas Vogelpoth from the LPBF Process and Systems Engineering group at Fraunhofer ILT. “We are adding new functions to parts made with 3D printing: permeability as a designable feature.”
The advantage over conventional metal foams or fabric structures lies in the complete integration of porous zones directly in the component. This eliminates the need for joining processes, which are often associated with functional disadvantages such as increased thermal or electrical resistance. In addition, complex geometries and internal structures remain feasible.
“Our plan is for users to tell us how much permeability is required in which component areas, and we will supply the appropriate design and process parameters,” says Vogelpoth.
Hydrogen technology in particular is a potential field of application. In electrolysers, functional layers with defined permeabilities could be additively manufactured, thus reducing the number of individual parts. The ILT sees further applications in areas such as heat exchangers, toolmaking and chemical process engineering.
At the Laser World of Photonics 2025 in Munich (June 24-27), the ILT will be demonstrating the technology using an exhibit with integrated pore zones. The researchers’ aim is to be able to adapt process parameters to the application – tailored to the respective permeability requirements. The approach is intended to give small and medium-sized companies in particular access to this technology.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
