A research team at Saarland University has developed a method that significantly improves the quality of metal components produced via 3D printing. The core of this approach is the targeted use of sound waves during the powder bed-based laser melting process. In his doctoral thesis, manufacturing engineer Oliver Maurer demonstrated that acoustically induced vibrations homogenize the metal powder prior to melting, thereby enhancing the microstructure and increasing the strength of the printed parts.
Unlike mechanical shaking, sound allows precise control of movement. A speaker integrated into the 3D printer emits low-frequency sound onto the substrate plate. The resulting vertical vibrations compact the powder in a controlled manner before the laser melts each layer. This leads to reduced pore formation, a finer crystal structure, and improved dimensional accuracy of the final components. This is particularly advantageous for complex small parts in sectors such as aerospace, automotive, or medical technology, where high structural and load-bearing requirements apply.
Continuous vibration promotes the formation of shorter, more densely interconnected crystallites, improving mechanical properties. At the same time, the method reduces post-processing needs and lowers the reject rate.
“Due to the acoustic vibrations, the crystallites encounter neighboring crystallites more quickly, resulting in a better length-to-width ratio and a denser network. This refines the metal structure, making it stronger and more stable,” explains Oliver Maurer.
However, precisely tuning the process parameters—from laser power to sound frequency—remains complex.
“It was already known from laser cladding that sound can improve manufacturing results. There, metal structures are built on a base material by welding wire or powder,” says Maurer.
“But this method is also transferable to other alloys. It’s essential to tailor the entire process, especially the acoustic frequency, to the specific application,” Maurer adds.
The method has so far been tested with an aluminum alloy but is generally applicable to other metals. The research team is currently seeking industry partners for technology transfer.
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