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TUM researchers are revolutionizing 3D printing of aluminum components!
TUM is starting a research project on additive manufacturing of aluminum to reduce cracking and strengthen aerospace.
TUM researchers are revolutionizing 3D printing of aluminum components!
On September 12, 2025, the Technical University of Munich (TUM) announced that it has launched an important research project called Aluminum from Additive Manufacturing (AlaAF) together with the Friedrich-Alexander University Erlangen-Nuremberg (FAU) and Colibrium Additive. This project is funded by the Federal Ministry of Education, Technology and Space with 1.17 million euros and aims to optimize the production of lightweight and resilient aluminum components for aerospace using industrial 3D printing.
The focus of the project is the Laser Powder Bed Fusion (LPBF) process. According to this innovative technology, metal powder is melted layer by layer into components using a laser. Great importance is placed on the freedom of design of the parts produced. One of the key problems that researchers are trying to address is cracking during the cooling of high-strength aluminum alloys, which makes their use in load-bearing structural elements much more difficult.
Technology and challenges
The AlaAF project brings together several institutions, including the sophisticated manufacturing techniques of the Fraunhofer Institute for Laser Technology (ILT). Complex die-casting tool inlays for large aluminum parts were developed here. The so-called PBF-LB/M technology enables the production of large die-casting molds, which are of central importance for the automotive industry. These forms must be thermally resilient, adaptable and resilient in order to meet the challenges of electric mobility.
The special steel L-40 required is crucial here, as it allows molds to be produced with conformal cooling. This innovation helps to minimize temperature peaks and significantly extend the life of the molds by reducing wear.
The AlaAF project uses a new approach that uses special additives in metal powder to form submicron ceramic particles. This technique results in a fine-grained microstructure that both reduces crack formation and improves the mechanical properties of the components. The aim is to achieve an overall weight that is lighter without losing resilience. Such innovations are particularly important in a sector that is undergoing significant change due to rising costs and the need for an energy transition.
Research and analysis
Another focus of TUM research is the use of neutron methods to examine materials. The FRM II research reactor enables scientists to analyze the phase distributions and the internal stresses in the printed materials. The combination of neutron experiments and mechanical stress as well as temperature variation helps to realistically represent industrial conditions and optimize the quality of the parts produced.
The team led by Dr. habil. Ralph Gilles at TUM is also dedicated to the development of process parameters for the LPBF process. FAU will analyze the printed materials in detail to further improve the mechanical properties and thus meet the long-term requirements of the aerospace industry.
Overall, the AlaAF project represents a significant step in materials research for aviation and shows the potential of additive manufacturing techniques to develop high-quality and sustainable solutions that can respond to the challenges of the future. The collaboration between universities and industry forms the basis for this future-oriented research and development.