IWK 3D Printing / Additive Manufacturing

3D printing / Additive Manufacturing

The research field 3D printing / Additive Manufacturing (AM) develops solutions for industry and academia along the entire 3D printing process chain; from the development and optimization of various AM processes, to the design and optimization of components, to the qualification and parameter development of newly developed materials.

In many projects from the other departments, there are also useful opportunities where the know-how of additive manufacturing can be included. Be it, for example, only to produce a prototype. This includes for instance prototyping or rapid tooling using additive manufacturing.

Core Competencies

AM process development and optimization (SLS, APF, FFF, FRP, Hybrid LMD, ADAM, FEM)
AM materials development (parameter determination)
Design for AM (AM-compatible design)
Automated design (workflows, configurators)
Simulations for AM (surface and topology optimization, simulation)
Reverse engineering (via 3D scan or CT scan)
Technical consulting
Fesibility studies (from first idea to manufacturing of single parts, small series production)
Digitalization (smart factory, simulation)
Training (Bachelor and Master studies, CAS courses, OSTLAB)

Equipment

Additive Manufacturing machines

EOS FORMIGA P 110 Velocis – Selective Laser Sintering (SLS)

Laser type: CO₂, 30W
Typical layer thicknesses: 0.06 - 0.10 - 0.12 mm
Print volume: 200 × 250 × 330 mm
Build rate: up to 1.2 l/h

Download Flyer SLS EOS Formiga P 110
Download Flyer Automatisiertes Strahlen von Bauteilen (SLS)

ARBURG freeformer 200-3X - ARBURG plastic freeformer (AKF)

2 extruder (2 materials in granulate form)
Nozzle diameter: 0.15 - 0.2 - 0.25 mm
Typical layer thicknesses: 0.2 to 0.35 mm
Print volume: 189 × 134 × 230 mm
Nozzle temperature: up to 350°C
Build chamber temperature: up to 120°C

Download Flyer freeformer

Original Prusa SL1S SPEED – Masked Stereolithography (MSLA)

Monochrome LCD: 5.96'', 2560×1620p, 405 nm
Layer thickness: 0.025 - 0.1 mm
Print volume: 127 × 80 × 150 mm
Layer exposure time: 1.3 – 2.4 s (depending on material and layer height)

EVO-tech EVO-lizer EL-102 – Fused Filament Fabrication (FFF)

2 extruders (for up to 2 materials)
Nozzle diameter: 0.3 - 0.7 mm
Typical layer thickness: 0.1 - 0.5 mm
Print volume: 500 x 400 x 510 mm
Nozzle temperature: up to 420°C (suitable for high performance plastics)
Print bed temperature: up to 200°C
Build chamber temperature: up to 100°C
Integrated filament drying

Ultimaker S5 – Fused Filament Fabrication (FFF)

2 extruders with filament sensors (2 materials)
Printcore system for quick exchange of printheads
Nozzle diameter: 0.25, 0.4, 0.8 mm
Typical layer thicknesses: 0.02 - 0.6 mm
Print volume: 330 x 240 x 300 mm
Nozzle temperature: up to 280°C
Print bed temperature: up to 140°C

Markforged Mark Two – Fiber Reinforced Printing (FRP)

Printhead with filament and fiber feed
Nozzle diameter: 0.4 mm (filament) and 0.9 mm (fiber)
Typical layer thickness: 0.1 - 0.2 mm
Print volume: 320 x 132 x 154 mm

Various other filament-based 3D printers

Download Flyer Reverse Engineering und Qualitätssicherung
Download Flyer Chocoformer

Post-processing

Ultrasonic cleaning bath for support removal
ARTEKA blasting cabin with rotary drum for automated blasting
Equipment for dyeing and surface treatment of SLS components

Software

Siemens NX (CAD)
Materialise Magics (Pre-Processing)
Various slicing tools (Simplify3D, Cura, PrusaSlicer, ...)
Digimat-AM from MSC Software (Simulation)

Videos

Automated design for 3D printing: potentials and case studies (German Presentation)

The time-consuming design process is increasingly becoming the biggest bottleneck for many 3D printing applications. This presentation will use various case studies to show how design can be automated using new digital tools.

Innovative showcases from the field of mechanical engineering

Daniel Omidvarkarjan presents innovative showcases from the mechanical engineering sector, such as turbine impellers and fluid components, and summarises the most important findings of the study.

Chocoformer

The chocolate 3D printer developed at the OST Ostschweizer Fachhochschule enables the professional production of three-dimensional delicacies made of fine chocolate.

For more information, visit www.chocoformer.com

Technical papers

Journals

2024

Download Selektives Lasersintern
Grimm, S., Omidvarkarjan, D., KunststoffXtra 09-10/2024, p. 6-7

Download 5-Achsen-3D-Druck
Omidvarkarjan, D., KunststoffXtra 07-08/2024, p. 6-7

2023

Download Automatisierte Konstruktionstools
Grünenfelder, P., Omidvarkarjan, D., Grimm, S., KunststoffXtra 11-12/2023, p. 16-17

2021

Download Online-Temperaturmessung beim SLS
Büse, U., Grimm, S., KunststoffXtra 12/2021, p. 4-5