Additive large-scale components New 3D printing with fiber-reinforced compounds

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Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF

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Lightweight construction is a design philosophy that becomes applicable in the project "ECO2-LInE" with the construction of some components. Here, an innovative Additive Manufacturing named SEAM also aids ...

In the above-mentioned research project, ten partners will develop large components made of sustainable, natural fiber-reinforced plastics for cross-industry, varying applications using high-speed 3D printing SEAM (Screw Extrusion Additive Manufacturing). To fully exploit the lightweight construction potential, the design will take into account the process-dependent material and component properties. In doing so, the ubiquitous topic of CO₂ savings is achieved not only through the targeted weight reduction and new constructions, but also through a systematic examination and adjustment of the entire manufacturing chain. The Fraunhofer Institute for Machine Tools and Forming Technology IWU, in cooperation with S.K.M. Informatik GmbH, is responsible for the development of the 3D printing process. The Fraunhofer Institute for Structural Durability and System Reliability LBF is primarily responsible for the material development.

Innovative lightweight components with practical properties

Consequently, the set project goals are sustainability and resource conservation, automation and digital networking, cost-effectiveness, and productivity increase. However, the transfer foundations for industrial manufacturing, the industrial qualification of the additive SEAM process through the development and testing of the specific applications of the demonstrators for the partners are also included, as it continues. The demonstrators developed in the course of the project – a sustainable reclining bench, lightweight seats, pickup attachments, and a novel frame element for transition systems of rail vehicles – will of course also be tested for their suitability for use. For example, mechanical strength tests will have to demonstrate their load-bearing capacity for the series. In this context, the LBF contributes its lightweight construction expertise in design, prototype construction, and in the context of a holistic assessment and analysis of materials, components, and systems. Among other things, the LBF experts will vibrationally analyze the new seats and develop flame protection for the frame elements through suitably tailored additive developments.

More about the project partners and components

Upon successful completion of the project, the involved users could market the sustainably manufactured natural fiber-reinforced components, expand their production, and thus secure jobs in Germany, according to the researchers. By the way, the project already started in May 2021 and is supported by the Federal Ministry for Economic Affairs and Energy's Technology Transfer Program Lightweight Construction. Under the leadership of Martin Schnierle, Managing Director of Hermann Schnierle GmbH, the ten consortium partners from research and industry are working together over a period of three years. Thus, the Fraunhofer LBF is primarily responsible for the material development, and the Fraunhofer IWU, in collaboration with S.K.M. Informatik GmbH, is responsible for the 3D printing process development. The latter is responsible for the software programming of the printer in the project. The users of the natural fiber-reinforced components are Hermann Schnierle GmbH (sustainable reclining bench and lightweight seats), Fiftyten (pickup attachments), and Hübner GmbH & Co. KG (novel frame elements for transition systems of rail vehicles). Associated partners include Biowert Industrie GmbH, J. Rettenmaier & Söhne GmbH + Co KG, 3M Deutschland GmbH, and Metrom Mechatronische Maschinen GmbH, as we finally learn.