Fraunhofer IWU showcases high-temperature LPBF and function-integrated lightweight parts

Das Fraunhofer IWU is highlighting two topics at Formnext 2025: hard-to-process materials for aerospace in Laser Powder Bed Fusion (LPBF) and additively manufactured components with integrated electrical functions. The presentation also has a practical demonstrator character: the modular exhibition stand is made entirely of 3D-printed elements from biocompostable plastic and recyclable polypropylene and will be reused at the institute after the trade fair.

Technically decisive is a new high-temperature LPBF system at the Dresden institute site. Depending on material requirements, the system allows powder bed preheating up to 1,200 °C. This enables reliable processing of high-melting and corrosion-resistant refractory metals such as tungsten as well as intermetallic materials like titanium aluminide. While these materials have often been processed in practice via Electron Beam Melting (EBM), LPBF at high preheating temperatures enables finer resolution, thin-walled structures, and more targeted microstructure control. This opens up lighter, temperature- and wear-resistant designs for engine components, turbocharger systems, or heat exchangers.

In parallel, the team led by project manager Dr. Florian Bittner is addressing particle-reinforced aluminum matrix composites (AMCs). Silicon carbide particles incorporated into the aluminum powder improve tribological properties while keeping density low—of interest for aerospace and automotive. In addition, IWU is developing process windows for the heat-resistant Al alloy Constellium Aheadd HT2, designed for application temperatures of around 250 to 300 °C, to produce fine LPBF structures with stable component quality.

A practical example of large-format printing is provided by a rear shelf unit developed together with MOSOLF Special Vehicles and manufactured using the SEAM process: using the Mercedes Vito as an example, it saves 26.5 kilograms including hardware and preserves payload capacity. The exhibition stand demonstrates the cost-effectiveness of such approaches: from around 55 kilograms of PP granulate, shelving elements and counters were produced in just under 13 hours; the modular system is lightweight, load-bearing, and reusable. Together, the exhibits show how high-temperature LPBF and large-format extrusion printing expand material diversity, component integration, and resource efficiency in additive process chains.