Initial situation

Users of PBF-LB systems are confronted with the problem that current process parameter sets are based on static approaches and are specified by the system manufacturer. The developed process parameter sets are made available by the system manufacturers for a fee via licenses. Individual customization and direct access to the process parameters are usually not possible. From the user's point of view, this results in two challenges. On the one hand, the transfer of a process parameter set to the same starting material but with different powder properties cannot be implemented flexibly and quickly, as corresponding process parameter sets have not yet been developed or provided by the system manufacturers. On the other hand, a disadvantage of static process parameter approaches is that the individual geometry of the components cannot be taken into account, or only to a limited extent.

The company 2oneLab, a Darmstadt-based manufacturer of 3D printers, has already successfully launched the 2CREATE metal 3D printer and the 2Build CAM software on the market a year ago. Together with the PTW at TU Darmstadt, the DiSer project aims to tackle the challenges mentioned above.

Objective

The proposed project specifically addresses these challenges by developing an open platform for the exchange of qualified process parameter sets and by developing digital services for component and customer-specific process parameter adaptation and for the traceability of product development processes. The 2Connect web app is being developed as a platform and central interface between the stakeholders (plant manufacturers, powder manufacturers, users and customers) and between the existing hardware (2CREATE) and software (2Build). For the first time, this makes it possible for all information from the 2Build CAM software and the associated 2CREATE hardware to be stored centrally and made available to users.

Approach

In this project, PTW aims to create a deeper and more comprehensive understanding of the key target variables of the PBF-LB process in order to better exploit the potential of additive manufacturing and to improve this process in terms of resource efficiency. In addition, the implementation of a cross-process chain network and database structure is being promoted in the sense of open data exchange via standardized interfaces, which is being developed as a prototype for the 2oneLab use cases as part of this project. The target variables are productivity, component quality and resource efficiency. In previous research projects, some of these target variables have already been individually investigated and their influence validated using prototype components as examples. The existing knowledge about the target variables of productivity and quality is to be deepened in this project and expanded with findings on the topic of resource efficiency. PTW's long-term research objective is to be able to describe the interactions between the individual target variables in order to exploit the potential of additive manufacturing more extensively.

Acknowledgments
This project is funded by the Hessian State Chancellery – Minister for Digital Strategy and Development (funding line Distr@l: Strengthen digitization – live transfer). We thank you for the opportunity to work on this project.

Funding source

Consortium partners