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Additive Manufacturing

E 100.SLM
Additive Manufacturing of Parts Made of Copper Alloys Using High Laser Power
Selective Laser Melting (SLM) is a powder-based additive manufacturing technique for the manufacture of metal parts. Amongst other areas, SLM is used in industry to manufacture tooling moulds from tool steel with conformal cooling channels. These tooling moulds minimise cycle times and enhance the quality of plastic parts. Due to the high thermal conductivity of copper, tool inserts made of copper alloys are often used to conduct the heat out of the tool. The most efficient way of cooling would be an insert made of copper combined with conformal cooling channels.

Until now however, copper alloys could not be processed by SLM with properties required for tooling or any other application. Although the melting point of copper alloys is lower compared to steels, copper alloys require a significantly higher laser power for the laser melting process. This is due to the low absorption of laser radiation and the high thermal conductivity of copper. At Fraunhofer ILT a SLM machine with a laser of 1kW maximum output power has been set up to process copper alloys to dense parts.

Contact Person
Dipl. -Ing. David Becker
Phone +49 241 8906-568
Fraunhofer Institute for Laser Technology ILT

E 100.SLM
Rapid Manufacturing of Aluminium Parts for Serial Production via Selective Laser Melting (SLM)
The additive manufacturing technology Selective Laser Melting (SLM) is used for direct fabrication of metal-based functional components. SLM is currently being qualified for aluminium alloys, for example AlSi10Mg, which is a common die-cast aluminium alloy. For serial-identical functional prototypes, individual parts, and small series, SLM permits an economic alternative for mould and die production like die-casting. The application of these components made using SLM demands that the mechanical properties attain similar values as conventionally built parts.

Contact Person
Dipl.-Ing. Damien Buchbinder
Phone +49 241 8906-488
Fraunhofer Institute for Laser Technology ILT

E 100.CO2
Rapid Manufacturing of Bioresorbable Bone Substitute Implants
Rapid Manufacturing of individual bone substitude implants via Selective Laser Melting (SLM) is developed for common metal materials in implantology (Titanium (-alloys) or Cobalt-Chrome-alloys). These implants are permanent implants which have to be removed in a second operation or will stay in the human body. The clinically preferred strategy is the regenerative therapy. This means that the self healing process of the body is used for healing of large bone defects. A new approach follows this strategy. The SLM process is adapted for bioresorbable materials (Biopolymer, Bioceramic) to build individual implants which will dissolve in the body and be replaced by new bone. The additive manufacturing makes it possible to realize an interconnected porous structure in the implant which is necessary for a vascularisation of the implant and a complete substitution by new bone. Using Selective Laser Melting a new technique for manufacturing of individual bioresorbable implants with interconnected porous structure will be possible.

Contact Person
Dipl. Phys. Simon Höges
Phone +49 241 8906-360
Fraunhofer Institute for Laser Technology ILT
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