Wire-based 3D Printing Technology for Sustainable Mobility: Insights into Research at LKR – Interview with Dr. Stephan Ucsnik

The LKR Leichtmetallkompetenzzentrum Ranshofen (Light Metal Competence Center), a subsidiary of the AIT Austrian Institute of Technology, is dedicated to the research and development of light metal alloys and their sustainable processing. A particular focus is on wire-based additive manufacturing (WAM), which enables the efficient production of large-scale components from aluminum, magnesium, and titanium. In an interview with 3Druck.com, Dr. Stephan Ucsnik discusses the possibilities of additive manufacturing for light metal components, technological developments in wire-based manufacturing, and their significance for sustainable mobility, as well as LKR’s role in research and industry.

A central method in metal additive manufacturing is the wire-based technology (WAM), which, unlike powder-based processes, uses welding wires as the starting material. This allows for higher deposition rates and theoretically unlimited component sizes. By adapting conventional welding equipment, complex geometries can be built up layer by layer without the need for expensive casting molds. This offers significant potential, particularly for the automotive and aerospace industries, by enabling lightweight components with integrated functions.

LKR’s research includes the development of specialized aluminum, magnesium, and titanium wires optimized for the additive manufacturing process. Both standardized welding consumables and custom-developed wire alloys are used to enhance the mechanical properties of the manufactured components. Additionally, the center is working on integrating sensors and electronics directly into components during production to create intelligent structures.

A key research area is the development of innovative hydrogen storage solutions within the LH2-WAM-Tank and MAST3RBoost projects. While LH2-WAM-Tank focuses on developing lightweight liquid hydrogen tanks made from aluminum using wire-based additive manufacturing (WAM), MAST3RBoost aims to optimize ultra-porous materials to improve storage capacity. Both projects seek to create more efficient and lightweight storage solutions that advance the use of hydrogen in aviation and other mobility applications.

With its extensive expertise in alloy development, process optimization, and material characterization, LKR plays a significant role in advancing additive manufacturing for light metals and contributes to the implementation of sustainable mobility solutions. As a member of the AM Austria technology platform, LKR also fosters knowledge exchange between research and industry and supports the further development of additive manufacturing in Austria.

Interview with Dr. Stephan Ucsnik

In an interview with 3Druck.com, Dr. Stephan Ucsnik, Deputy Managing Director and Senior Engineer at LKR, as well as Thematic Coordinator for Wire-based AM, discusses the potential of additive manufacturing for lightweight metal components and their industrial applications. He elaborates on the development of new wire alloys, technological advances in wire-based manufacturing, and their significance for sustainable mobility. Additionally, he highlights LKR’s role in research and its contribution as a member of AM Austria.

How does additive manufacturing contribute to the development of functionally integrated lightweight components, and which material properties play a key role?

Additive manufacturing is a young and promising technology that has recently expanded not only technical possibilities but also efficiency and cost-effectiveness. It enables the realization of geometries that would not be economically viable with conventional manufacturing methods. These include the integration of cavities, channels, lattice structures, or the combination of multiple components into a single part. Additionally, it allows for the use of different materials and the combination of various AM processes to incorporate additional functionalities, such as intelligent sensors or conductor paths, directly into components or walls. Coupled with geometry optimization, these features maximize lightweight potential while minimizing component weight.

What progress has LKR made in the development and optimization of wire alloys for wire-based additive manufacturing (WAM), and what advantages do they offer for industrial applications?

Current filler materials for wire-based additive manufacturing (Directed Energy Deposition, DED) originate from welding technology and are designed for single-, double-, or multi-layer fusion welding. Since the thermal conditions and cooling rates of fusion welding and DED differ significantly during processing, the final component properties can vary despite using identical feedstock wire. LKR Ranshofen has strategically focused on researching and optimizing new wire alloys, particularly for the lightweight metals aluminum, magnesium, and titanium.

In the field of aluminum alloys, a composition has been defined that achieves high performance without the use of critical or non-sustainable elements. Additionally, by improving melt quality and eliminating lubricants and waxes, difficult-to-weld alloys such as AA7075 have been made weldable. Currently, LKR is working with partners to extend these developments to magnesium and titanium.

What future advancements or breakthroughs in additive manufacturing of lightweight metals could have a significant impact on sustainable mobility solutions?

Sustainable mobility solutions require technological advantages, time efficiency, and economic viability to achieve widespread adoption. Current challenges include developing feedstock materials specifically optimized for AM processes and property requirements, increasing build rates to around 5 kg/h for aluminum alloys, and advancing hybrid approaches.

Hybrid approaches aim to use conventional material substrates such as cast parts, extrusions, or sheets as a base, integrating cost-effective manufacturing processes with localized specialized contours or geometries. These developments will enable the rapid and cost-effective realization of components in early development phases (batch sizes of 0–10 or 10–100 units), significantly shortening development cycles. If production volume, build speed, and manufacturing costs align, additive manufacturing could also be utilized as a final production process.

For large-scale geometries, such as tank systems with integrated functions and/or structural reinforcement elements, DED will serve as a key technology. It has potential applications in mobility solutions for aircraft, trucks, or construction machinery (“Yellow Goods”).

As a member of AM Austria, through which initiatives and projects do you aim to promote the further development and targeted use of additive manufacturing technology in Austria?

AM Austria brings together key players from research and industry, facilitating intensive exchanges and the generation of new ideas through various workshops. This exchange lays the foundation for new approaches and enables innovative projects to be initiated in collaboration with partners. These projects ultimately lead to technically and economically relevant development partnerships between research and industry.

LKR is currently focusing on the development and production of large, complex, and capital-intensive components made from aluminum and titanium using enhanced AM manufacturing technologies. The goal is to create competitive solutions that strengthen Austria’s industry in global technology leadership.

Furthermore, LKR has been integrating new methods from the fields of data science, machine learning, and artificial intelligence into its research agenda for the past four years. These new tools form the basis for digitized quality assurance and the qualification of processes and components. This enables inline quality inspection and machine control, replacing traditional 100% or service cycle-based quality assurance with event-based quality assurance—an essential advantage in terms of efficiency and speed.

Through these measures, LKR, as a member of AM Austria, will continue to advance the development and targeted application of additive manufacturing technology in Austria.

Here you can find more information about the LKR Light Metal Competence Center Ranshofen and its current projects.