The Fraunhofer Institute for Laser Technology ILT in Aachen is presenting a range of new developments in the field of metal additive manufacturing at the Formnext 2025 trade fair in Frankfurt. The goal of these research projects is to make additive manufacturing processes more robust, cost-effective, and functional – from high-performance materials for fusion reactors to intelligent structures with integrated sensors.
One of the institute’s main focuses is the laser powder bed fusion (LPBF) process for difficult-to-process materials such as tungsten. As part of the EU project DURABLE, ILT is investigating the production of monolithic and hybrid components made of tungsten and copper alloys that can withstand the high thermal loads found in fusion systems. Through optimized process control, it is possible to produce nearly crack-free, high-density structures.
“Whether we develop a demonstrator or a production series, we focus our R&D at Fraunhofer ILT on making processes faster, more robust and ensuring high component quality,” explains Dr. Tim Lantzsch, head of the Laser Powder Bed Fusion (LPBF) department at Fraunhofer ILT. “We think about additive manufacturing from the perspective of component function, combining material, process, and data, reducing costs per part, and increasing quality and availability. We see ourselves as problem solvers and process developers, from the initial idea to stable production at our industrial partners.”
“The benefits lie in longer component life, less rework, and lower risk at joining points, which is a prerequisite for extending maintenance intervals and reducing costs per operating hour,” says Niklas Prätzsch, group manager LPBF – Process & Systems Engineering at Fraunhofer ILT.
In the field of laser material deposition, the institute is also presenting new approaches. The SCaRB process combines high-speed laser material deposition (EHLA) with roller smoothing in a single process step. This allows the surface to be plastically densified and smoothed directly during coating.
“This saves time, tools, and material,” says Glushych, explaining the advantages. “At the same time, SCaRB can specifically influence the microstructure and internal stresses. This improves the wear and corrosion resistance and increases the fatigue strength of coated components.”
“The innovation lies in using the residual heat from the EHLA process to melt a deposited PEEK layer in the immediately following step. A nozzle technology developed at Fraunhofer ILT is used for this purpose, which enables homogeneous application. This hybrid coating system combines the properties of two individually adjustable functional layers,” explains Rebar Hama-Saleh Abdullah, research associate at Fraunhofer ILT.
Furthermore, ILT is working on PFAS-free multilayer systems that combine metallic EHLA coatings with polymer-based PEEK layers. These hybrid structures offer new possibilities for wear- and corrosion-resistant applications, such as in wind turbines and mechanical engineering.
“The adhesive strength between metal and polymer is achieved by clamping the plastic to the rough surface specifically created using the EHLA process,” explains Dr. Christian Vedder, Head of the Surface Technology and Ablation Department at Fraunhofer ILT.
“These sensors are located exactly where data is most useful, even in areas that would be inaccessible with conventional manufacturing,” summarizes Dr. Samuel Moritz Fink, group manager Thin Film Processing at Fraunhofer ILT. “This enables us to monitor conditions during operation, do predictive maintenance, and provide greater operational reliability. At the same time, system complexity is reduced because separate superstructures, cables, or external measuring points are no longer necessary. Target industries range from aerospace and energy to mechanical engineering.”
Another research focus is the printing of integrated sensors in metal components. These allow real-time monitoring of stress and load during operation, enabling condition monitoring and predictive maintenance.
“New materials are the key to leveraging the particular strengths of SLS, namely maximum design freedom and freedom from support structures, in more and more industries. With our modified machines, we can efficiently qualify these materials and thus overcome the chicken-and-egg problem of industrial plants,” explains Vera Rothmund from the Application Development group at Fraunhofer ILT.
“At Fraunhofer ILT, we see ourselves as a partner to industry: we develop customized processes and technologies to solve key challenges in metal 3D printing – from productivity and quality assurance to cost-effectiveness – together with companies,” says Dr. Thomas Schopphoven, head of Laser Material Deposition Department at Fraunhofer ILT.
With these developments, Fraunhofer ILT underscores its role as an industrial partner for process development and qualification of additive manufacturing technologies.
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