Additive manufacturing

The additive manufacturing of composites offers the advantages of design freedom, flexibility and product customization. It consequently has significant potential for novel industrial applications.

We are researching the challenges that need to be overcome for a successful industrial implementation of additive manufacturing, such as limited material options, difficulties in combining different materials, the strong influence of the printing strategy on the final properties, and long manufacturing times.

Formulation development and material functionalization

Multiple different polymers can be used as a matrix material for extrusion-based additive manufacturing (AM). We produce, modify and optimize biobased and biodegradable polymers (e.g. PLA, PHB) for AM processes. High-performance thermoplastics (e.g. PEEK, PPS, PPSU) reinforced with short glass or carbon fibers are suitable for demanding applications, in which traditional engineering thermoplastics cannot be applied. Metals or carbon-based materials can be used as fillers, for example in electrically conductive composites. Processability, and especially the melt viscosity of the composite, plays an important role.

Besides traditional particles for functionalization, nanomaterials can also be used. Carbon nanotubes (CNTs) enable electrically conductive composites with considerably lower filler concentrations than can be achieved with metal fibers or conductive carbon black. As a result, the viscosity of the melt and the mechanical properties of the composite compared to the matrix material are less strongly affected.

2-Component 3d-printed USB flash drive with an integrated electrical conducting path and an LED
© Fraunhofer ICT
2-Component 3d-printed USB flash drive with an integrated electrical conducting path and an LED

Process development

The target properties of printed parts depend on the complete production chain, from polymer compounding and filament production through to the printing of the parts. We monitor the entire production chain and optimize technological and economic aspects of both the material composition and the production processes.

By combining conventional short-fiber-reinforced or unreinforced polymers with continuous glass- or carbon-fiber reinforcements, the mechanical properties of additively manufactured parts can be significantly improved. Using our state-of-the-art filament manufacturing and additive manufacturing equipment, we can tailor the material and the process to the requirements of our customers.

Mini extruder
Mini extruder

Our expertise and offer

We offer our customers services ranging from basic investigations and feasibility studies through to process engineering implementation.

  • Feasibility studies and benchmark testing
  • Formulation development (filaments, granules)
  • Determination of suitable processing parameters
  • Consultancy in process and component design
  • Characterization of materials and components

Our state-of-the-art processing equipment includes the machinery for formulation development (small-scale mixers, kneaders and extruders), a filament production line and several one- and two-component additive manufacturing machines to process unreinforced, short-fiber-reinforced and continuous-fiber-reinforced materials.

Our involvement in the Karlsruhe Research Factory for AI-Integrated Production offers us the unique opportunity to conduct applied research in the future topic of "intelligent production" using our processes.

Karlsruhe Research Factory (karlsruher-forschungsfabrik.de)