Fraunhofer Institute for Production Technology IPT
From semi-finished product to ready-to-use component
Additively manufactured metal components are initially produced in a semi-finished state and do not yet offer the dimensional accuracy, surface quality, or functionality required for industrial applications. Only through targeted post-processing can they become ready-to-use components.
Why post-processing is indispensable
At Fraunhofer IPT, we manufacture these components using laser powder bed fusion (LPBF), laser metal deposition with wire (LMD-w), or wire arc additive manufacturing (WAAM). After the parts are 3D printed in a powder bed, the support structures must be removed. In all of the processes, surfaces must be smoothed and, if necessary, functionally structured.
Mechanical processes such as milling, grinding, sandblasting, or vibratory grinding ensure dimensional accuracy and smooth surfaces – an absolute prerequisite for precise assembly. Laser structuring gives surfaces additional functionality: The micro- and nanostructures introduced can, for example, control the transport of liquids in lab-on-a-chip systems or reduce friction on sliding surfaces.
Integrated process chains for additive manufacturing and post-processing
The quality of an additively manufactured component depends on how well all manufacturing steps interact. At Fraunhofer IPT, we develop integrated process chains in which additive and subtractive processes are combined systematically.
By integrating high-performance measurement technology and methods into the process chain, we can improve the efficiency and productivity of manufacturing and enhance the quality of even complex production processes. We have state-of-the-art equipment and devices at our disposal, for example, for measuring geometry and mechanical properties such as hardness, tensile strength, and microstructure.
Using real-world component examples, we can analyze the process steps, improve interfaces, and optimize machining parameters. This methodical approach increases efficiency, enhances process reliability, and brings advantages for the use of additive processes in industrial series production.
Repair and maintenance
Additive manufacturing is not only suitable for new production, but also for the repair and maintenance of worn metal components. Damaged components can be restored through targeted material application – precisely, resource-efficiently, and economically. In this way, additive manufacturing can make industrial production processes significantly more sustainable.
Our services
Based on integrated process chains, we can
- develop customized additive manufacturing processes,
- plan hybrid process chains,
- conduct feasibility studies,
- evaluate industrial components,
- manufacture prototypes and test them in our measurement laboratories and
- integrate the processes into industrial series production.
This transforms raw components into ready-to-use end products that meet the highest standards of precision, function, and quality.