MADE-3D

Multi – Material design using 3D printing

Additive manufacturing (AM) has the economic potential to complement conventional manufacturing processes, especially in the production of complex, multi-material (MM) components. To exploit the full benefits of optimized lightweight structures, it is usually required to use multi-materials with different physical properties.
Still, multi-material combinations from conventional processes are not transferable to AM, due to residual stresses, cracks, or thermal expansion rates of the different materials. Furthermore, geometric shape and position tolerances, as well as recycling strategies for powder waste, post-processed waste, and the component itself are not yet defined.
Based on the 3D printing processes PBF-LB and DED, this project aims at the concurrent engineering of designing processable multi-material optimized alloys, development of design concepts for multi-material structures with specific simulations for load cases and topology optimizations, and an extensive process adaption. Alloy and process development will be aided by advanced integrated computational material engineering approaches that combine thermodynamics, microstructure, and process simulations through machine-/active learning, resulting in shorter material development cycles. For bulk and powder materials, recycling of multi-material components via innovative concepts will promote the sustainability of multi-material additive manufacturing. This adaption will lead to increased process reliability and speed, enabling the dissemination of MM manufacturing in AM for the entire industry.
The consortium brings a wide range of international expertise to the table, from materials research and digitization to the manufacture of multi-material components. It consists of startups, research institutions and market leaders in additive manufacturing. Industrial end-users cover automotive, aerospace and aeronautic applications with specific use cases.

Within the project AMIRES was involved in the project’s preparatory phase and negotiations and is responsible for administrative project management and for communication and dissemination.

• Partners:
  • UNIVERSITAET PADERBORN, Germany
  • SLM SOLUTIONS GROUP AG, Germany
  • FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG e.V, Germany
  • PANEPISTIMIO AIGAIOU, Greece
  • F3NICE, Italy
  • EXPONENTIAL TECHNOLOGIES, Latvia
  • QUESTEK EUROPE AB, Sweden
  • AVL LIST GMBH, Austria
  • SAFRAN ADDITIVE MANUFACTURING CAMPUS, France
  • COMMISSARIAT A L ENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES, France
  • AMIRES S.R.O., Czech Republic
  • CSEM CENTRE SUISSE D’ELECTRONIQUE ET DE MICROTECHNIQUE SA – RECHERCHE ET DEVELOPPEMENT, Switzerland
  • SKYRORA LTD, United Kingdom

This project has received funding from the European Union’s Horizon Europe research and innovation programme under grant agreement No 101091911.