DDMC2016
Berlin, March 16 - 17, 2016
Proceedings
DDMC 20163rd Fraunhofer Direct Digital Manufacturing Conference
Organized by the Fraunhofer Additive Manufacturing Alliance, the bi-annual Direct Digital Manufacturing Conference brings together researchers, educators and practitioners from around the world. The conference covers the entire range of topics in additive manufacturing, starting with methodologies, design and simulation,right up to more application-specific topics, e.g. from the realm of medical engineering and electronics.
PREFACE
DDMC 2016 again featured a powerful technical program with 6 keynotes, 54 presentations in 16 sessions and 12 posters. DDMC 2016 was a truly immersive experience for the well over 150 conference delegates participating. For the conference proceedings the papers are structured according to the 15 conference sessions, each presenting the current state of the art in additive manufacturing.I would like to take this opportunity to thank all the authors for their contributions as well as the members of the scientific committee for the time and effortthey put in the double-blind review process, thus ensuring the excellent quality of presentations. My congratulations go to the winners of the Best Paper Award (Chris Bailey, Stoyan Stoyanov, Tim Tilford and Georgios Tourloukis from the University of Greenwich/ UK for their paper on “Modelling Methodologies for Quality Assessment of 3D Inkjet Printed Electronic Products”) and Best Poster Award (Łukasz Żrodowski, Bartłomiej Wysocki et al from the Warsaw University of Technology/ Poland for their work on “The Novel Scanning Strategy For Fabrication Metallic Glasses By Selective Laser Melting”).
Last not least please be reminded that the next DDMC conference will be taking place March 14-15, 2018 in Berlin. I look forward to seeing you there!
Sincerely,Dr.-Ing. Bernhard MuellerDDMC 2016 CONFERENCE CHAIRSpokesman Fraunhofer Additive Manufacturing Alliance
IMPRINT
Contact:Dr.-Ing. Bernhard MuellerFraunhofer Additive Manufacturing Alliancec/o Fraunhofer Institute for Machine Tools and Forming Technology IWUNoethnitzer Straße 4401187 DresdenGermanyPhone +49 351 4772-2136Fax +49 351 4772-2303E-Mail [email protected] http://www.generativ.fraunhofer.de
Bibliographic information published by Die Deutsche NationalbibliothekDie Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliografic data is available in the Internet at www.dnb.de.
ISBN (E-Book): 978-3-8396-1001-5
© by Fraunhofer Verlag, 2016Fraunhofer Information-Centre for Regional Planning and Building Construction IRBP.O. Box 80 04 69, 70504 StuttgartNobelstrasse 12, 70569 StuttgartPhone 0711 970-2500Fax 0711 970-2508E-Mail [email protected] http://verlag.fraunhofer.de
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CONTENT
TABLE OF CONTENTS
Session 1.1: Novel Applications
Additive Manufacturing of Architectural Façade Elements 21Sven PfeifferTU Berlin, Institute for Architecture, Germany
Dispenser and Aerosoljet Printed Electrical Functionalities 25 Ines Dani1, Lukas Stepien1, Aljoscha Roch1, Christoph Leyens1,2
1Fraunhofer IWS, Germany; 2Technische Universität Dresden
3D Printing Embedded Sensors Using Solid State Welding 29Mark Ira Norfolk1, Justin Wenning1, Adam Hehr2, Hilary Johnson1
1Fabrisonic LLC, Columbus, USA; 2The Ohio State University, Columbus, USA
Session 1.2: Design
Aerospace Case Study on Topology Optimization for Additive Manufacturing 37Michael Süß1, Christine Schöne2, Ralph Stelzer2, Burghardt Klöden1, Alexander Kirchner1, Thomas Weißgärber1, Bernd Kieback1,2
1Fraunhofer IFAM Institutsteil Dresden, Germany; 2Technische Universität Dresden, Germany
Development of Light Weight Lattice Structure Using 3D-printing 43Umesh Gandhi, Recep Gorguluarslan, Yuyang SongToyota Technical Center, United States of America
Session 1.3: Powder
From Powders to Metal Parts Through Selective Laser Melting: Comparison of Several Commercial Al-12Si Alloy Powders 53Olivier Dellea1, Philippe Berne1, Maria Averyanova2, Romain Soulas1, Pascal Revirand1, Pascal Fugier1, François Tardif1
1CEA LITEN, France; 23D SYSTEMS France
Effects on Properties of Metal Powders for Laser Beam Melting Along the Powder Process Chain 59Max Lutter-Günther, Christian Seidel, Gunther ReinhartFraunhofer IWU, Germany
About the Influence of Powder Properties at the Selective Laser Melting Process 67Sebastian Matthes, Robert Kahlenberg, Christian Straube, Simon Jahnifw Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
Session 2.1: EBM
Numerical Investigations of Selective Electron Beam Melting on the Powder Scale 75 Matthias Markl, Andreas Bauereiß, Abha Rai, Carolin KörnerChair of Metals Science and Technology, Friedrich-Alexander Universität Erlangen-Nürnberg, Germany
Influence of Scanning Strategy on Properties of Titaniumalumindes Produced by Selective Electron Beam Melting 81Vera Juechter1, Carolin Körner2
1WTM, University of Erlangen-Nürnberg, Germany; 2WTM, University of Erlangen-Nürnberg, Germany
Process and Quality Supervision for EBM Production Applications 87Ulric Ljungblad, Johan Backlund, Patrik OhldinArcam AB, Sweden
Processing Specifics in Electron Beam Melting of TiAl 93Burghardt Kloeden1, Alexander Kirchner1, Thomas Weißgärber1, Bernd Kieback1, Sara Biamino2, Giorgio Baudana2
1Fraunhofer IFAM, Dresden, Germany; 2Politecnico di Torino, Italy
Session 2.2: Simulation
Comparison of Approaches for Structural Simulation of Additively Manufactured Metal Parts Based on Simufact.welding 101Hendrik Schafstall1, Pavel Khazan1, Patrick Mehmert1, Thomas Töppel2, Richard Kordaß2
1simufact engineering GmbH, Germany; 2Fraunhofer-Institute for Machine Tools and Forming Technology IWU, Germany
Pre-compensation of Warpage for Additive Manufacturing 109Christoph Schmutzler1, Fabian Bayerlein1, Stephan Janson1, Christian Seidel1,2, Michael F. Zaeh1
1Technical University Munich, Institute for Machine Tools and Industrial Management, Germany; 2Fraunhofer IWU, Germany
Design Against Distortion of SLM Parts Based on Simplified Numerical Modelling Methodologies 117Pedro Alvarez, Joseba Ecenarro, Iñaki Setien, Maria San Sebastian, Alberto EcheverriaIK4-LORTEK, Spain
Simulation Aided Manufacturing: Scanning Strategies for Low Distortion in Laser Beam Melting Processes 123Nils Keller, John Schlasche, Hongxiao Xu, Vasily PloshikhinAirbus Endowed Chair for Integrative Simulation and Engineering of Materials and Processes (ISEMP), University of Bremen, Germany
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
Session 2.3: Quality
Improving Part Quality in LBM Processes by Geometry Based Scanparameter Adaption 131Hongxiao Xu1, Vasily Ploshikhin1, Alexander Kulikov2, Ruslan Loginov2, Benjamin Günther3
1University of Bremen, Germany; 2Neue Materialien Bayreuth GmbH, Germany; 3Concept Laser GmbH, Germany
Surface Modification by Laser Re-melting of Parts Produced by Electron Beam Melting 137Marcin Madeja, Jarosław Kurzac, Edward ChlebusWrocław University of Technology, Poland
Influence of Ambient Conditions on the Laser Based Powder Bed Fusion Process 143Simon Jahn, Robert Kahlenberg, Christian StraubeGünter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany
Microstructure and Mechanical Properties of Inconel 718 for the Manufacture of Aircraft Parts by Selective Laser Melting 149Tomasz Kurzynowski, Jaroslaw Kurzac, Konrad Gruber, Bogumila Kuznicka, Edward ChlebusWroclaw University of Technology, Poland
Session 3.1: Novel Materials
Fabrication of Cu-Al-Ni-Mn Shape-Memory Parts by Selective Laser Melting 159Tobias Gustmann1, A. Neves2, U. Kühn1, P. Gargarella2, C. S. Kiminami2, C. Bolfarini2, J. Eckert1, S. Pauly1
1IFW Dresden, Germany; 2UFSCar, Brazil
SLM Processing of 14 Ni (200 Grade) Maraging Steel 165Philipp Stoll1, Adriaan Spierings1, Konrad Wegener2, Stefan Polster3, Mathias Gebauer3
1inspire AG, Switzerland; 2IWF - Institut für Werkzeugmaschinen und Fertigung der ETH Zürich, Switzerland; 3Fraunhofer IWU, Germany
Process Parameters for Selective Laser Melting of AgCu7 171Harald Rieper1, Andreas Gebhardt2, Brent Stucker1
1University of Louisville, USA; 2Aachen University of Applied Sciences, Germany
3D-printing Using Conditioned Miscanthus – Application for Special Packaging 177Diana Klemm, Henning Zeidler, Wolfgang Meyer, Gunther GlowaBECKMANN-INSTITUT für Technologieentwicklung e. V., Germany
Session 3.2: Process Chains
Investigation and Assessment of a Laser Additive Manufacturing based Process Chain by the example of an Injection Mold 187Fritz Klocke1, Reinhart Poprawe2, Robert Schmitt1, Andres Gasser2, Kristian Arntz1, Markus Grosse Böckmann1, Nils Klingbeil1, Johannes Kerkhoff1, Thomas Vollmer1, Maximilian Wegener1, Moritz Alkhayat2
1Fraunhofer IPT, Germany; 2Fraunhofer ILT, Germany
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
Process Analysis and Optimization of Current AM Technologies on the Example of Laser Sintering 193Michael ten Hompel1, Christian Prasse2, Mathias Rotgeri2, Eric Klemp3
1Chair of Materials Handling and Warehousing, TU Dortmund, Germany; 2Fraunhofer Institute for Material Flow and Logistics, Germany; 3Direct Manufacturing Research Center, Universität Paderborn, Germany
Influencing Factors on Quality of Titanium Components Manufactured by Laser Melting 199Simon Jahn1, Christian Straube1, Felix Gemse1, Vanessa Seyda2, Dirk Herzog2, Claus Emmelmann2
1Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany; 2Technische Universität Hamburg-Harburg, iLAS Institut für Laser- und Anlagensystemtechnik, Germany
Process Parameter Development for Industrial Hybrid Machine 205Benjamin Bax, Lukas Löber, Holger Perfahl, Marcel Pawlik, David Albert, Martin Reisacher, Patrick DiederichSauer GmbH (DMG MORI), Germany
Session 3.3: Quality Methods
Quality Control Process for Additive Manufactured Parts 213Tobias Grimm1, Georg Wiora2, Gerd Witt1
1Institute of Product Engineering, Manufacturing Technology, University of Duisburg-Essen, Duisburg, Germany; 2NanoFocus AG, Oberhausen, Germany
Topology Examination for Additive Manufactured Aluminum Components 219Rene Bastian Lippert, Roland LachmayerLeibniz Universität Hannover, Germany
Practical Powder Analysis for Metal Powder Bed Based AM 225Claus Aumund-Kopp, Daniela Zibelius, Juan IsazaFraunhofer IFAM, Germany
In-Situ Surface Roughness Measurement of Laser Beam Melted Parts – a Feasibility Study of Layer Image Analysis 231Joschka zur Jacobsmühlen1, Stefan Kleszczynski2, Alexander Ladewig3, Gerd Witt2, Dorit Merhof1
1RWTH Aachen University, Germany; 2University of Duisburg-Essen, Duisburg, Germany; 3MTU Aero Engines AG, Munich, Germany
Session 4.1: Ceramics
Lithography-based Ceramic Manufacturing: Layer-by-layer to Dense and Precise Ceramic Parts 241Martin Schwentenwein, Johannes HomaLithoz GmbH, Austria
Equipment, Material and Processes for UV-DLP-based Additive Manufacturing of Two-component Ceramic Green Bodies and Dense Structures 245Patrick Springer1, Eric Schwarzer2, Oliver Refle1, Hans-Jürgen Richter2
1Fraunhofer IPA, Stuttgart, Germany; 2Fraunhofer IKTS, Dresden, Germany
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
Development of Photo-curable Ceramic Suspensions Usable for Additive Manufacturing of Components 255Eric Schwarzer, Uwe Scheithauer, Matthias Ahlhelm, Anja Härtel, Hans-Jürgen Richter, Tassilo MoritzFraunhofer IKTS, Germany
Multi-material Approach to Integrate Ceramic Boxed Temperature-sensitive Components in Laser Beam Melted Structures for Bio and Other Applications 261Holger Lausch1, Thomas Töppel2, Romy Petters2, Bernd Gronde1, Mathias Herrmann1, Kerstin Funke2
1Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden/Hermsdorf, Germany; 2Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz/Dresden,Germany
Session 4.2: Process Innovations
Selective Electron Beam Melting of the Single Crystalline Nickel-based Superalloy CMSX-4 273Carolin Körner, Markus Ramsperger, Abha RaiUniversity of Erlangen-Nuremberg, Germany
Correlation Analysis of Different Building Parameters on the Part Properties of Parts Built by Simultaneous Laser Beam Melting of Polymers 279Tobias Laumer1,2,3, Thomas Stichel1,2, Michael Schmidt1,2,4
1Bayerisches Laserzentrum, Erlangen, Germany; 2CRC 814 Additive Fertigung, Friedrich-Alexander-University, Erlangen-Nürnberg, Germany; 3SAOT Erlangen Graduate School in Advanced Optical Technologies, Erlangen, Germany; 4LPT Institute of Photonic Technologies, Friedrich-Alexander-University, Erlangen-Nürnberg, Germany
Multi Material Processing in Laser Beam Melting 285Christine Anstätt1, Christian Seidel1,2, Gunter Reinhart1,2
1Faunhofer IWU, Germany; 2Company iwb, Munich, Germany
Aluminium Matrix Nano Composites by DMLS: Effect of the Nanoparticles on the Microstructure and Mechanical Properties. 291Alberta Aversa1, Giulio Marchese1, Diego Manfredi2, Flaviana Calignano2, Elisa Ambrosio2, Sara Biamino1, Paolo Fino1, Matteo Pavese1, Massimo Lorusso2
1Politecnico di Torino, Italy; 2Istituto Italiano di Tecnologia, Italy
Session 4.3: Polymer
New Materials for Laser Sintering: Processing conditions of Polyethylene and Polyoxymethylene 301Andreas Wegner1,21University of Duisburg-Essen, Germany; 2AM Polymer Research UG
Thiol-ene Reactions in Stereolithography, an Alternative to Epoxy and Acrylic Resins? 307Holger Leonards1, Marlene Runte1, Andreas Hoffmann1,2, Sascha Engelhardt1,2, Martin Wehner1, Arnold Gillner1
1Fraunhofer Institute for Laser Technology, Aachen; 2Chair for Laser Technology, RWTH Aachen University
Optimization Considerations for FDM 3D Printing of Fiber Reinforced Polymeric Materials 311Uwe Popp, Brando OkoloIndmatec GmbH, Germany
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed
1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016
March 2016, Berlin / GERwww.ddmc-fraunhofer.de
Additive Manufacturing of Architectural Façade Elements
Sven Pfeiffer
Technical University of Berlin, Berlin, Germany
[email protected], +49 30 314 25255
Abstract
The research paper focuses on the use of additive manufacturing for the design and production of architectural
façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,
inspired by traditional buildings and forced by climate change predictions, however, shows the importance for
architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-
efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly
criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in
generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.
As with additive manufacturing it is not necessary to produce a large number of equal components, building
elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which
they are used. In the presented research-by design project architects in collaboration with external partners explore
the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements
which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling
flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality
and aesthetic unprecedented in traditional manufacturing processes.
1 Context
Due to global challenges of climate change, dwindling
resources and an accelerated urbanization, the planning
and fabrication processes in the building sector face an
increasing transformation and research pressure. The
main problem of the building industry (10% of BIP) is
its resource inefficiency. The buildings sector is the
largest energy-consuming sector, accounting for over
one-third of final energy consumption globally and an
equally important source of carbon dioxide (CO2)
emissions [1]. Many traditional building materials have
a high environmental footprint and building processes
use a wide array of technologies which are rarely
integrated. The reasons lie in the size and economic
pressures on the one-off product “building” and its
immobility, which put borders on a further
automatization of large-scale fabrication processes. The
traditionally specialized functions of building elements
such as bricks or tiles inevitably raise the costs and
resources for on-site assembly processes (e.g. masonry
construction) and frequently involve different stages in
their production. In addition to this, sub-systems with
different functions and life-spans (e.g. construction and
installation) have to be integrated. A sustainable
transformation of the building sector will have to
overcome these problems posed by traditional
fabrication processes.
2 Additive Fabrication in Architectural
design and the Building Industry
Whereas additive manufacturing processes have been
widely introduced in high-tech sectors such as airplane
and automotive industries [2], the building sector is in
many areas characterized by traditional production
methods. In building, 3D printing is not commonly
encountered due to issues of cost and of scale. Until
recently, additive fabrication has been mainly used in
architecture to produce scaled representations of the
actual design. The shift from a scale model to the 1:1-
Scale of a building includes a substantial examination of
the physical properties of printable materials and the
lifetime of printed building parts. Nevertheless, as
technology progresses, additive manufacturing for
architectonic applications with small numbers of
elements could be economically feasible as tooling and
storage costs disappear. Whereas production costs for
one cubic meter in stereolithography and laser sintering
lie at over 30K €, other processes such as FDM (Fused
Deposition Modeling) ranges at costs of 2000 €/m3 [3].
Since the mid-nineties a few universities and companies
have started to attempt to apply additive fabrication in
architecture or construction. Most research goes into
various FDM processes, by which a building material is
deposited in layers. The extrusion head is moved in
relation to the construction platform. The shape of the
element is defined in outline and the enclosed area then
filled in. Different kinds of material can be used with
this method such as plastics, concrete or ceramic paste.
A variation on this system is known as “contour
crafting”[4][5] . In the Contour Crafting process, fixed