Schall revolutionizes 3D printing: components for aviation more stable and precise!

Schall revolutionizes 3D printing: components for aviation more stable and precise!

The challenges in 3D printing of components for safety-relevant areas such as aerospace and vehicle construction are considerable. Despite advanced technologies, these components are rarely used due to quality problems. A research team at the Chair of Manufacturing Engineering at Saarland University, led by Professor Dirk Bähre, has made valuable progress in improving component quality.

Under the leadership of doctoral student Oliver Maurer, sound is used in a novel process to increase the quality of small metal components in powder bed 3D printing. According to a report from Saarland University, sound is used to compact metal powder during the melting process by a laser. This leads to increased stability and homogeneity of the components produced, which is crucial for their further application. Integrating a speaker into the 3D printer creates targeted vibrations that significantly improve the properties of the printed material.

Quality improvement procedures

Using sound waves is similar to compacting concrete. The targeted sound vibration causes the metal powder particles to move closer together. The laser melts the compacted powder, resulting in a refined crystal structure and improved strength. Reports show that in addition to minimizing voids, this method also optimizes the microstructure of components and increases geometric accuracy. Fewer pores and a more homogeneous surface are the result of this innovative technology.

Another advantage is the faster availability of the components, as the new method requires less post-processing. Studies show that the sound vibrations make the melting process more controlled, which could reduce the internal stress of the components. This is of particular interest for small, complex-shaped components that are used in medical technology for prostheses, for example.

The process is not only suitable for certain alloys, but can also be transferred to other types of metal. Maurer has already published scientific articles on this technology and is looking for active partner companies to further develop and apply the process in practice.

Aerospace Prospects

In the context of aerospace, companies like Trumpf rely on additive manufacturing to make components lighter and more stable. Additive technology now has over 20% market share in this area and helps to minimize the high transport costs into space. State-of-the-art processes such as Laser Metal Fusion (LMF) and Laser Metal Deposition (LMD) enable precise designs that specifically only use material where it is needed. For example, a mount for communications satellites was made 55% lighter without losing stability.

Numerous companies are recognizing the value of improved 3D printing techniques for safety-critical applications. The developments at Saarland University offer promising approaches to solving existing problems and opening up new markets.