TU Dresden: Laser post-processing for 3D metal parts

New Processes Complex 3D-Printed Metal Parts Can Be Post-Processed

2026-08-21 Source: TU Dresden | Translated by AI 3 min Reading Time

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A European research consortium coordinated by TU Dresden is developing new methods for the post-processing of complex 3D-printed metal components...

Behind the acronym Clasco is a project based on laser processing techniques, aiming to enable the reliable and application-specific post-processing of even complex metal parts produced by 3D printers. TU Dresden took the lead...(Image: German Materials Society) — Behind the acronym Clasco is a project based on laser processing techniques, aiming to enable the reliable and application-specific post-processing of even complex metal parts produced by 3D printers. TU Dresden took the lead...
(Image: German Materials Society)

As part of the Horizon Europe project Clasco—"Climate Neutral and Digitalised Laser Based Surface Functionalisation of Parts with Complex Geometry"—scientists led by the Technical University of Dresden (TUD) have found a new approach for post-processing complex 3D-printed metal components. The project focused on developing a complete process chain, according to reports. To achieve this, the researchers combined processes such as laser polishing, laser microstructuring, process monitoring, digital twins, and artificial intelligence into an integrated manufacturing concept. They then tested it on components for aerospace and medical applications. However, 3D-printed metal components often have comparatively rough surfaces, as the experts pointed out. For demanding applications, manufacturers must therefore specifically process these surfaces—a task that becomes increasingly challenging with more complex parts.

SKZ Whitepaper_Mission Additive Manufacturing_Coverbild

Two Laser Processes, One Groundbreaking Success

First, laser polishing smooths the rough surface without contact. Then, the Direct Laser Interference Patterning (DLIP) process creates precisely defined microstructures on selected areas of the component. Using these structures, the researchers were able to tailor the surface properties to the specific application, as explained. This demonstrated that even the surfaces of complex 3D-printed metal components can be designed as needed while simultaneously digitally monitoring the processing. This creates an important foundation for making such components more efficiently usable for demanding industrial applications in the future.

Lightweight Construction Was Also a Focus

The researchers already utilized the design freedom of additive manufacturing during the construction of the components to save material and weight. Through topology optimization, they achieved significant weight reductions on two demonstrators for aerospace applications. They reduced the weight of an Airbus A350 mounting bracket by nearly 53 percent and designed a corresponding lever to be about 38 percent lighter, as highlighted. After additive manufacturing, the surfaces were processed using the newly developed laser-based process chain. Laser polishing reduced the typical surface roughness immediately after 3D printing from about ten to 30 micrometers to less than one micrometer. In a second processing step, DLIP created regular structures in the micrometer range. This allowed the scientists to specifically alter properties such as wettability, corrosion behavior, or the interaction of implant surfaces with biological materials.

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Date: 08.12.2025

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