Annual report 2023
Focus on sustainability

Industrializing AM 4U
www.iapt.fraunhofer.deContents

Contents
Editorial ����������������������������������������������������������������������������� 4
Sustainability at Fraunhofer IAPT ����������������������������������� 6
Initiatives at Fraunhofer IAPT ��������������������������������������� 10»For industry to respect planetary boundaries,
it needs to be sustainable. It needs to develop
circular processes that re-use, re-purpose andrecycle natural resources, cut down on waste
and reduce environmental impact.

Shaping the future together ����������������������������������������� 12
Improving quality of life ����������������������������������������������� 14
Higher-quality treatment at a lower cost ��������������������� 16
Transfer to industry via online training��������������������������� 18
Rapid repair ����������������������������������������������������������������� 20
AM in the automotive industry ������������������������������������� 22
Advisory board members����������������������������������������������� 24

Sustainability means reducing energy consumption and greenhouse emissions, […]Technologies like AI and additive manufacturing can play a significant role in this by
optimising resource efficiency and minimisingwaste.1«

The institute in figures ������������������������������������������������� 26
Scientific publications ��������������������������������������������������� 28
Research for members ��������������������������������������������������� 30
Making production more sustainable ������������������������� 31
Patents granted��������������������������������������������������������������� 32
Partnerships ������������������������������������������������������������������� 33
Publishing notes ����������������������������������������������������������� 36

2

3

Editorial»

Our research in the Hamburg
Metropolitan Region reaches theentire economic area of the EU.«
Prof. Ingomar Kelbassa,
institute director

From research
to industry
Bridging the gap between research and industry is fundamental to the work that Fraunhofer IAPT does every day.
Whether we are working from the perspective of virtualisation, process chain automation orprocess qualification, or with technologies like L-PBF, Sinter AM, DED or Polymer AM in mind,
we are consistently pursuing the goal of unlocking additive manufacturing for industrial use ona large scale. We are forging many different paths as we work towards this.
We are training the experts of the future and celebrating a number of doctorates. We areattending and organising conferences and events, publishing documentation and registering
patents. We are finding inspiration from our advisory board, and we are cooperating withresearch institutions and industrial partners.

4

In the future fields we work in, we are in constant dialogue with the branches of industry inwhich the use of additive manufacturing is particularly relevant from a commercial perspective.
We are developing our own initiatives that go beyond the established paths.
Annual report 2023 provide an insight into the diversity of our work at the institute, in the
Hamburg Metropolitan Region and in the European Economic Area.
We hope you enjoy reading, and we invite you to share your own ideas and the challenges you
have faced in your additive manufacturing journey.
Prof. Ingomar Kelbassa and the Fraunhofer IAPT team5

Artist’s impression of the planned new building in Bergedorf, Hamburg

Sustainability at
Fraunhofer IAPT
How sustainable is additive manufacturingand how sustainable are we?
These are questions that we think it is important to consider in our research and in our interactions at the institute. For example, our innovative strength and our projects – such as theIAMHH ® initiative – have brought us to the point where we need a new building in which
we can reproduce the entire production route. It goes without saying that we want this building
to have a sustainable design.

6

That’s why we are using sustainable materials like wood and steel instead of concrete, andwhy we plan to implement an intelligent electricity and consumption management system.
We are using the roof areas for photovoltaic systems with a total capacity of 162 KWp anda storage capacity of 222 Ah. There will be three charging points with 22 kW to power up
to six electric cars at the same time. We plan to heat the building with heat pumps and use
heat recovery for ventilation and cooling.
We are also retrofitting our existing buildings with photovoltaic systems that are
expected to meet around a third of the energy demand in these locations.

The little ringed plover used to live on flat shores and by unspoilt
rivers. Today, it almost exclusively inhabits alternative, man-madehabitats. When drawing up our development plan, we counted
two breeding pairs; these will be given gravel areas on the roofof the new building with water that will not dry out in summer.

7

7 questions for Vivien
What is your job?
Project coordinator for sustainability
at Fraunhofer IAPT

What did you study?
The potential of AM ranges from resource efficiency to reduced quantities of waste and a circular economy

Sustainability
requires coordination
Balancing aspirations and reality: our sustainability
management expert puts AM to the test.

8

For my bachelor’s degree, I studied businessadministration at the Harz University of Applied
Sciences in Wernigerode. I did my master’s
degree in management, specialising in sustainability, at the Westphalian University of Applied
Sciences in Gelsenkirchen.

What motivates you?
I think climate change is one of the greatest
challenges of our time, so ideally I hope to makea small contribution towards reducing global
warming. I also think additive manufacturing
is an exciting field of research when it comesto energy and resource efficiency.

How old are you?
26

In one of our future fields, Energy, we are researching ways to decarbonise production byminimising material and energy use, and we are seeking out solutions relating to recycling
and the circular economy. We are developing and improving production processes for plastics
and metals, designing innovative components with optimised functions and testing ways toprocess new materials.

City, country or suburbs?

It was in this context that we advertised the position of project coordinator for sustainability
at the end of last year. We have since welcomed Vivien Großkopf as the institute’s expert insustainability management. Vivien is researching additive manufacturing throughout the
product life cycle at our organisation, and engages in a number of activities in this context –these include taking measurements in the production environment, assessing and preparing
measurement results, and undertaking environmental auditing.

What do you like to do outside work?

City

Car, bicycle or train?
Electric car

In my free time, I like to play the piano or accordion
and go to the gym, and in summer I go stand-up
paddleboarding on the Alster lake.
At the weekend, you will often find me at theWeserstadion as I’m a big Werder Bremen fan.

9

Initiatives at Fraunhofer IAPT

Industrialized Additive
Manufacturing Hub Hamburg
The IAMHH® initiative
Since Ingomar Kelbassa took up his role in
April 2022, Fraunhofer IAPT has joined thecity of Hamburg and other major players frombusiness and research in driving the initiative
known as IAMHH®, or Industrialized Additive Manufacturing Hub Hamburg. Its goal
is to create and establish an ecosystem for theindustrialisation of 3D printing in the Hamburg
Metropolitan Region. Alongside this, joint
research with a project volume in the orderof around €100 million is being targeted in
the first five years.
The future-focused topics and application
areas being addressed as part of this joint
research include Life Science, Mobility, Energy
and Climate Protection, as well as Security
and Defence. In addition to the joint projects,
there are plans for physical hubs in the Hamburg Metropolitan Region that will provide
members with a space to meet and undertake
joint research and development activities.

10

The initiative will also place a sharper focus
on further education and training: new professorships in production technology fields
are set to be created, alongside further education opportunities in a non-academic settingwith the aim of training specialist personnel.
More than 70 letters of intent from industry
and research have been submitted for the
initiative.
The next steps to be taken with regard tolaunching initial pilot projects and founding
an association will be finalised in 2024. This
follows the IAMHH® initiative being presented
to the administrators of the Hamburg Science,
Research, Equality and Districts Authority(BWFGB) and the Authority for Economy
and Innovation (BWI) at Hamburg City Hallon November 20, 2023, where it was warmly
received.

11

Shaping the future together

Shaping thefuture together
Industrialising AM 4U
At Fraunhofer IAPT, we are optimising industrial production
while contributing to the common good. Fuelled by expertise,creativity and courage, we are finding answers to the urgent
questions of the future.
We are industrialising additive manufacturing and designing
production environments to create value in a way that ensuresresilience and sustainability. We are currently focusing on the
future fields of Life Science, Mobility, Energy and Security and
Defence.
We consider the transfer of knowledge to industry to be justas important as our research. Here, we illustrate our approachwith the following selection of projects from our future fields.

Fraunhofer IAPT is industrialising additive manufacturing and designing production environments to create value in a way that
ensures resilience and sustainability

1213

NextGen Life Science

Improving quality of life
Mobility in the hands and feet can be reduced
by a range of joint conditions. The existingtreatment options primarily use drugs orarthrodesis to stiffen the joint. Both reduce
quality of life and generate high follow-up
costs due to the amount of care and therapy
involved.
If an implant needs to be used, there are
currently two options available on the market:
silicone types, which in most cases quickly
come loose and require a second intervention,or simply made standard implants, which
are only available in certain sizes and restrict
movement.
In the FingerKIt project, Fraunhofer IAPT, IKTS,
ITEM, IWM and MEVIS have succeeded in
manufacturing perfectly fitting implants that
do not slip and can re-establish previous levelsof mobility. The individually adjusted joint
implants open up a new form of treatment
for rheumatoid arthritis or traumas.

Patient-specific finger joint implant made fromalumina toughened zirconia (ATZ)

Dr. Philipp Imgrundtel. +49 40 484010-740
philipp.imgrund@

The FingerKIt project
The aim is to make customised finger joint
implants quickly and safely in a certified,
automated process chain that uses metallic or
ceramic materials. For this purpose, Fraunhofer
MEVIS has created AI-supported softwarethat calculates three-dimensional models of
the finger bones based on two-dimensional
X-rays and corrects potentially incorrect finger
positions.
Perfectly fitting implants re-establish previous finger mobility without slipping

Drawing on the finger model, researchers at
Fraunhofer IAPT created the individual implantdesign using AI and brought it to life with 3D
printing. Due to the extremely fine and delicate structures involved, the researchers used
metal binder jetting to build up the layers of
the components, which were then sintered –in other words, compacted and strengthened.
Fraunhofer IKTS produced the implants ina near net shape manufacturing process sothat they were as close as possible to thefinal shape design and required only a small
amount of reworking. Thanks to the expertiseprovided by Fraunhofer IKTS, ceramic materials could also be used: these are processedusing slip casting, a special ceramic forming
technique.
Fraunhofer ITEM takes care of any issues
relating to biological compatibility and certification of the implants, while Fraunhofer IWM
is responsible for simulating the mechanicalloads.

Innovations at Fraunhofer IAPTThe researchers at Fraunhofer IAPT have developed several innovations in the course of the project. These include
AI-based calculation of a three-dimensional implant design
based on 2D templates, something that now has a patentpending. The process technology is another special development: as the structure of the implant shaft is very delicate, theteam at Fraunhofer IAPT has chosen to use metal binder jetting
for titanium as the 3D printing method. This enables the small
and complex implants to be manufactured with high precision.
At the same time, the surface of the shaft can be structured ina way that incorporates into the bone more easily. In addition,
the method minimises any reworking of the articular surfaces,
which must be as smooth and frictionless as possible.

The world’s only centre of its kindWith the goal of rapid transfer to clinical and industrial practice in mind, all of the institutes worked together to develop
cross-institute, standardised digital documentation of theirprocesses during the project. This resulted in the establishmentof a centre – the only one of its kind in the Fraunhofer-Gesellschaft and in the world – for the AI-based development
and certification-compliant evaluation of custom implants.

»

The FingerKIt project hascreated significant processes
and methods that can be usedboth for the developmentof individual finger implants
and for various other implantdevelopments.«
Prof. Mark Lenz
Clinic for Trauma, Hand and Reconstructive Surgery,
Jena University Hospital

iapt.fraunhofer.de

14

15

NextGen Life Science

Project overview
The DigiMed project involved developing AI software solutions
that extract the relevant information about the defect frommedical image data (CBCT data) and generate a 3D modelof the skull. Based on this model, the orbital floor is reconstructed and an intact model of the skull with the implant isgenerated. Automatic generation is a two-stage process: virtual reconstruction uses a statistical shape model (SSM), while
the process of generating the implant design uses anatomical
characteristics.
The new workflow allows the digital process of generating
the implant to be partially automated. The entire digital value
chain for the production of implants was demonstrated usinga hypothetical medical application scenario in a laboratoryenvironment. The process behind the digital value chain waspresented at the same time as the physical process chain. Data
from the UKE and public databases was used to create a statistical shape model for this purpose.

A continuous process chain for manufacturing patient-specific implants was automated for the first time

Improving quality and efficiency

Higher-quality treatment
at a lower cost
Patient-specific implants

Phillip Gromzig

tel. +49 40 484010-742

In oral and maxillofacial surgery, treatment
with implants is standard practice. But commercially available standardised implants failto take account of the complex anatomical
characteristics demonstrated by facial bones,
and show some significant shortcomings in
geometry, fit and quality. For many indications, individually designed implants madethrough additive manufacturing offer a moresustainable way to treat patients.

In the DigiMed project, Fraunhofer IAPT
worked with the University Medical Center
Hamburg-Eppendorf (UKE) and the Helmut
Schmidt University/University of the Federal
Armed Forces Hamburg (HSU/UniBw H) todevelop a workflow aimed at significantly
improving the fit of implants as well as thequality of treatment experienced by patients.
In addition, a continuous process chain for
manufacturing patient-specific implants was
automated for the first time, using the reconstruction of the orbital floor as an example.

Digital value chains outperform conventional approaches bysome distance when it comes to efficiency and quality, achieving reductions of up to 50% in current preparation times of
10 days from imaging to operation. Additionally, the cost andduration of the production process are reduced by up to 40%
and quality is improved significantly due to the optimised fit,making it possible to reduce surgery time by as much as 20%.
Patients benefit from more rapid treatment as well as higher
implant quality and a better fit. In hospitals, the new workflow
makes life easier for staff when it comes to making a diagnosis, preparing implants and planning operations.

Fraunhofer IAPT is creating a new basis for improving the quality and reproducibility of components made through additive
manufacturing by automating the development of processparameters for additive manufacturing while taking account of
the individual implant geometry. This means adaptive processparameters can be applied to individual layers. In the area ofcomponent reworking, it has also been possible to create afully automated concept for surface post-treatment.
In another field of work, an MDR-compliant qualification andcertification concept for the entire value chain was successfully developed. Both the digital and physical process chains
and their interfaces, as well as the individual processes, were
examined in the overall context and linked together based on
the requirements for a certification route.

»

Digitalisation, 3D manufacturing and innovative materials
are bringing about a paradigm
shift in the medical world. We
are moving away from standardised implant geometries
and towards patient-specifictreatment solutions.«
Phillip Gromzig
Head of NextGen Life Science,
Fraunhofer IAPT

phillip.gromzig@
iapt.fraunhofer.de
Patient-specific reconstruction of the orbital floor

16

17

NextGen Energy

Transfer to industry
via online training
Learning paths for more sustainable products
The German federal government is promoting a shift to more sustainable production processes. »To ensure we can continue to live well in the future,« it says, »our consumption and our
production techniques must change.«2 But how is it possible to make changes while production
processes are actively taking place?

Funded by:
EIT Manufacturing (no. 23171)

Relevant expertise and qualified employees are a vital element in seizing the opportunities
presented by cutting-edge technology and making production processes more sustainable ona continuous basis. Comprehensive knowledge of the potential and limitations inherent in more
efficient technologies, such as additive manufacturing, enables innovations to be translated into
products that are functional and conserve resources.

Online qualification for advanced learners: additive manufacturing for new designs of heat exchangers

New products:
sustainable and cost-effective
Fraunhofer IAPT has taken an important step
towards teaching sustainable production techniques in the ADAA – Advanced Design for
Advanced Applications project. The Universityof Bologna, INEGI and Prima Additive havedeveloped a highly specialised training programme with funding from EIT Manufacturing
and under the leadership of Fraunhofer IAPT.
There are nine learning paths in total, aimed
primarily at designers and product managers.
The programme gives them the skills theyneed to identify suitable assemblies and develop sustainable, cost-effective products using
additive manufacturing.

Olaf Steinmeiertel. +49 40 484010-622
olaf.steinmeier@iapt.fraunhofer.de18

In addition, any interested learners can apply
their knowledge in practice and discover morein a workshop led by experts from the institutions involved.

Learning paths: Additive Manufacturing
for Product Designers

Awarded the EITM Non-Degree Label
Topology Optimization for AM
Biomimetic Design with AM
Compliant Mechanisms
Multi-Material Design with AM
Optimized Acoustics by AM
Design of AM Heat Exchangers
Design for Fiber-reinforced Printing
4D Printing of Materials
Design of AM Soft Robotics

Application scenario: heat pumps
The learning path entitled Design of Additive Manufacturing Heat Exchangers teaches
designers the fundamentals of heat exchangers and covers application areas in thenext-generation research area of Energy, suchas heat pumps. Additive manufacturing ofheat exchangers can improve the efficiency ofheat pumps throughout their life cycle. Aftercompleting the learning path, learners cantake the approaches that they have learned
and use them to optimise their own products.

The learning paths entitled Topology Optimization for Additive Manufacturing, Design of Additive Manufacturing Heat Exchangers and Multi-Material Design with Additive Manufacturing, plus the practical workshop, have been awarded the EITM Non-Degree Label by the European Institute of Innovation and Technology. Learners receive a certificate of participation after completing
each learning path.

»

In the highly competitive AM
environment, companies will
benefit hugely from training
in technical and commercial
innovations.«
John Stavridis
PhD Additive Applications Manager & Business Development,
Prima Additive

Availability

In the pilot phase, around 100 learners from all over the world successfullycompleted the programme. The Additive
Academy® at Fraunhofer IAPT offers thecourses as standalone elements or as partof a training programme compiled to meet
individual needs.
If you want to grow your team’s expertise,
feel free to get in touch with us at academy@iapt.fraunhofer.de.

19

NextGen Security and Defense

Layer-by-layer structure of theprong on the robotic arm of

Use cases in battle damage repair(BDR)

Role allocation for efficient
operations

The Additive Mobile Factory® is a mobile container production unit with a modular designthat can be used at different locations as astandalone, plug-and-play production cell. Allof the equipment is integrated in a standard
container and was easy to transport overland
to the AM Village in the Netherlands. Onceit had arrived, all the container needed was astandard power connection – and the Additive
Mobile Factory® was ready for operation.

The team first measured the faulty part andfollowed something known as the reachback
method by sending the initial measuring
results to Fraunhofer IAPT in Germany, which
adopted the role of operations base with AM
engineering expertise. Here, computer-aided
design (CAD) was used to turn the measured
values into a target geometry, which wasused as a basis for developing the production
strategy.

Each day, the AM Village presented users
from the military and the institute with newchallenges that soldiers typically face during
military operations. This includes damage tovehicles such as mine clearance machines or tocrankshaft heads, and faulty door fittings on
a combat vehicle. In each of these application
scenarios and others besides, it was possible to complete the repair with the Additive
Mobile Factory® within a few hours.

The qualified team of operators on site thenreceived a completed AM-ready file and started the repair using the 3D printing method of
cladding, also known as WAAM. The Additive
Mobile Factory® comes with integrated milling
equipment for reworking the manufactured
item, complementing the additive manufacturing techniques with subtractive ones.

the Additive Mobile Factory ®

The mobile container production unit can be used at different locations as a standalone, plug-and-play production cell

Rapid repair

Prong for the mine clearancemachine, printed using thecladding method

Christian Bartholomae

tel. +49 40 484010-627
christian.bartholomae@

The success of military operations in crisis-hit
regions relies on equipment being available
for use at all times. The operating conditions
make it possible to foresee which faults andequipment failures might arise as a result ofuse or damage, for instance. If repairs canbe made in the field in these cases, there isno need to make long journeys and use up
valuable logistical resources – and the time
gained in the process can be an operational
advantage.

Rapid repair of faulty equipment in the fieldusing the Additive Mobile Factory® helps toreduce what is known as the logistical footprint and increase the availability of materials.

At the AM Village 2023, a five-day workshop
organised by the European Defence Agency(EDA) and held in Ede in the Netherlands,
Fraunhofer IAPT presented the Additive
Mobile Factory® and demonstrated its performance in military settings.

At the AM Village initiated by the EDA,
Fraunhofer IAPT and AM experts from themilitary solved different repair problems every
day using the Additive Mobile Factory® andidentified the benefits of AM for military
operations.

The EDA’s EU Capability Development Priorities (CDP) identify additive manufacturing asa key technology with the potential to givearmed forces a crucial advantage in the fieldof military logistics. AM is therefore seen as atechnology with game-changing potential3.

Repairs in the field eliminate
long transport routes
As the application scenarios at the AM Village
show, the Additive Mobile Factory® reduces
the logistical work that would otherwise beneeded to supply spare parts and transport
faulty – then repaired – components over long
distances. In crisis-hit regions and war zones,
highly efficient and timely repairs to militaryequipment can be carried out in the field. The
Additive Mobile Factory® enables armed forces
to use AM methods wherever they need tocomplete their mission.

»

Ready-to-use equipment is essential
to the success of military operations.
Through the rapid repair of equipment in the field, the Additive Mobile
Factory® supports soldiers in completing their mission.«
Martin Huber
Project Manager, Deploy and Logistics,
European Defence Agency

iapt.fraunhofer.de20

21

NextGen Mobility

AM in the automotive
Formnext 2023 white paper
As an institute of the Fraunhofer-Gesellschaft,our goal is to bring technological innovations
into the circular flow of the economy for the
benefit of society. In an industrial context,
additive manufacturing technologies contribute to increased productivity, resource conservation, resilience and prosperity. This is truein particular of the future field of Mobility.
However, the benefits of additive manufacturing can only be fully realised if the industry
possesses the necessary expertise.

A white paper for the automotive industry
was drawn up on the occasion of last year’s
Formnext trade show. At around 20 pages
long, the document begins with an overview
of additive manufacturing as an addition toconventional production methods and brings
three key benefits into focus:

Knowledge transfer across industrial production is the goal of a project being pursued
by Mesago Messe Frankfurt (in the role ofpublisher) and in our future field of Mobility(with responsibility for content).

A guideline takes readers from the theory to
the successful use of additive manufacturing
in practice. In ten steps, manufacturing companies can learn what they need to consider
and what the key success factors are.

»Ina Ludwig

tel. +49 40 484010-768
ina.ludwig@
iapt.fraunhofer.de

22

Shorter innovation cycles
Freedom in design
Demand-based production

As a trade show organiser, we want
to reach specific target groups for thetechnologies that our exhibitors offer.
With this white paper, we have beenable to bring additive manufacturingbusiness cases and the Formnext trade
show to the attention of experts fromthe automotive industry.«
Sascha F. Wenzler
Vice President Formnext,
Mesago Messe Frankfurt GmbH

20 pages on additive manufacturing in the automotive industry

AM potential and success stories
Another major section of the content provides specific detailsof application areas in production throughout the automotive
life cycle. From prototypes made using additive manufacturing
to spare parts, and from production resources to tools made in
a 3D printer, the white paper identifies the potential for AM,
outlines the state of development in each case, and highlights
the amount of work required for implementation. AM theses
from renowned experts in the automotive industry and additive success stories from AUDI AG, Brose and Daimler Truck
round off the insights from the perspective of companies that
use AM.

Free download

The white paper takes the example of the automotive industry
to show how additive manufacturing supports productivity
and sustainability goals, and how it strengthens the positionof manufacturing companies against the international competition. The document is available to download free of charge
from the Fraunhofer IAPT website.

23

Advisory board members

Advisory board members
Fraunhofer IAPT would like to thank its advisory board for its hard
work. We are thrilled with the excellent partnership we have built,
and could not find any better words to describe it than those ofadvisory board member Stefanie Brickwede on LinkedIn:»

Stefanie Brickwede
Managing Director,
Mobility goes Additive e.V.

As a member of the advisoryboard, I am delighted to see
such a fantastic overview
of the projects that are currently being undertaken. It
is incredible what Ingomar
Kelbassa’s team is doing
for additive manufacturing
by driving forward specificprojects and founding somepromising start-ups.«

Dr. Klaus Kleine
Director Laser Application,
Coherent Inc., USA

Christoph Hauck
Member of the Executive Board,
toolcraft AG

Other advisory board membersin the reporting period

Dr. Tina Schlingmann
Regional Director EMEA: DACH & Benelux,
EOS GmbH Electro Optical Systems

Klaus von Lepel
Science, Research,
Equality and Districts Authority (BWFGB)Head of Research department / W2
Angela Titzrath
Hamburger Hafen und Logistik AG
Chair of the Executive Board

Dr. Karsten Heuser
Vice President Additive Manufacturing,
Siemens AG

24Prof. Andreas Timm-Giel
Hamburg University of Technology
President

25

The institute in figures

The institute in figures

The institute in figures

As of May 2nd, 2024

Overall budget
Institutional funding
14[million Euro]

12
10

12.3
10.1

10.9

9.7

10.7

9.8

4.3

million €

8

1.6 
0.4

	
Basic funding

Special allowancesInternal Fraunhofer programs

6

2.1 	
0.2 Special circumstances

4
2
0

18

19

20

Operating budget

21

22

23

Expenses

Investment budget

10.7

million €22.1 %
Business
incomemillion €2.0		
0.7		
3.8		

Economic income

Contribution from Hamburg	Staff

Material

Investments

External revenue

6.9

6.4
2.6		
1.8 

0.4 
0.08		Employees

EU

Miscellaneous

123

54
8 	

engineers and scientists

technical employees

15 	
46 

internal services

students

German federal government

26

27

Research publications

Scientificpublications

Conference papers 2023

BECKMANN, F., KALLAGE, P., FORSTER, O. EMMELMANN, C.,»Optimierte Schweißbarkeit von laseradditiv gefertigten
Aluminiumbauteilen mittels Adjustable Ring Mode Laser«,

COUSIN, F., PRAKASH, V. J., WEBER, J. U., KELBASSA, I.

Tagungsband DVS Congress 2023, Essen, ISBN: 978-3-(2023). Monitoring and control of laser-based additive

96144-230-0.

manufacturing using convolutional neural nets andreinforcement learning. In: Proceedings of LiM 2023.

BLUNK, Heiko and Arthur SEIBEL (2023). »Design guidelines for metalbinder jetting.« Progress in additive manufacturing (2023): 1–8.
HELMHOLZ, J. and VOGT, M. (2023). Evaluating Digital Assistance in Formof Augmented Reality for Manual Processes in the Metal Binder Jetting
Process Chain. In: Klahn, C; Meboldt, M; Ferchow, J. (pub.): Industrializing
Additive Manufacturing. Springer International Publishing, Cham 2024, p.
317–333.
JOHANNSEN, Jan, Christian LAUHOFF, Thomas NIENDORF, Christoph
SCHNITTER, Melanie STENZEL and Markus WEINMANN (2023). Laser beam
powder bed fusion of novel biomedical titanium/niobium/tantalum alloys:
Powder synthesis, microstructure evolution and mechanical properties. In:
Materials & Design, Volume 233, 2023, 112265, ISSN 0264-1275.
SPATZIER, J. and VOGT, M (2023). Wirtschaftliche Betrachtung vonAugmented Reality. In: ZWF 118 (2023) 6, p. 436–442. doi:10.1515/
zwf-2023-1083

WEBER, J.U., JÖRSS, H., JANKOWIAK, M. (2024). Systematical Assessment of Automation Potential in Additive

GROMZIG, P., BÖHM, C., IMGRUND, P., JOHANNSEN, J.,

Manufacturing Process Chains. In: KLAHN, C., MEBOLDT,KELBASSA, I., LINDECKE, P., NIGGEMANN, O. (2023).

M., FERCHOW, J. (eds) Industrializing Additive Manufac-

DigiMed: Digital workflow for Additive Manufacturing

turing. AMPA 2023. Springer Tracts in Additive Manufac-

of patient-specific implants. Transactions on Additive

turing. Springer, Cham.

Manufacturing Meets Medicine, 5(S1), 841.
BAUCH, A., HERZOG, D. (2023). Influence of temperature
GROMZIG, P., SMEETS, R. (2023). AI-based 3D-printing

and beam size on weld track shape in laser powder bed

strategies for patient specific implants in maxillofacial

fusion of pure copper using near-infrared laser system. J.

surgery: Innovation Input. In: AM Medical Days. Berlin,

Laser Appl. 1 February 2024; 36 (1): 012007.

December 11–12, 2023.
SASS, J.-O.; SELLIN, M.-L.; KAUERTZ, E.; JOHANNSEN, J.;HERZOG, D., KELBASSA, I., JOHANNSEN, J.; KOHLWES, P.;

WEINMANN, M.; STENZEL, M.; VOGEL, D.; JONITZ-HEINCKE,IMGRUND, P.; ROLDAN OSPINA, J. P.; SHIPLEY, J.; MAGNUS-

A.; BADER, R. (2023). Mechanical functionality and biocom-

SON, A. (2023). Lean Additive Manufacturing of Titanium

patibility of Ti-Nb-Ta alloys additively manufactured byParts in Larger Dimensions and Volumes. In: 15th Worldlaser beam powder bed fusion, Jahrestagung Deutsche

Conference on Titanium. Edinburgh, June 12–16, 2023.

Gesellschaft für Biomaterialien e.V., Jena.

JOHANNSEN, J., FAYYAZI, B., STENZEL M., WEINMANN, M.:

WEINMANN, M.; STENZEL, M.; JOHANNSEN, J. (2023).

»Additive Manufacturing and Mechanical Investigations

Laser beam powder bed fusion of novel biomedicalof Novel Biomedical Ti/Nb/Ta Alloys«. In: Proceedings ofTitanium/Niobium/Tantalum alloys, 5th International

DDMC 2023, Fraunhofer Verlag, ISBN 978-3-8396-1895-0, 2023.

Symposium Additive Manufacturing (ISAM), Dresden.

KOHLWES, P., LUDWIG, I., KOUHESTANI-FAROUJI, A.,

BÖHM, C.; WALTER, J.; JOHANNSEN, J.; GROMZIG, P;

HERZOG, D., EMMELMANN, C. 2023. Influence Analysis of

FUEST, S.; IMGRUND, P.; SMEETS, R.; NIGGEMANN, O.

Individual Powder Properties on L-PBF Process Capability.

(2023): »Development of an adaptive L-PBF and automated

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post-processing work flow for PSI «, Transactions on Additive

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WEINMANN, M., STENZEL, M., JOHANNSEN, J., SASS, J.-O.,

RÖHRICH, L.; EILERMANN, S.; SCHÖFER, F.; IMGRUND, P.;

SELLIN, M.-L., LORCK, C., PFÜTZNER, D., LEMBKE, U., KLUESS,GROMZIG, P.; BÖHM, C.; JOHANNSEN, J.; NGUYEN, A. M;

D., & BADER, R. (2023). Development of materials for additively

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manufactured hybrid knee implants. Transactions on

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»Development of AI-based segmentation and anatomicalreconstruction for orbital floor implants using medical

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image data«, Transactions on Additive ManufacturingM., KELBASSA, I. (2023): »Process Digitalization for Depo-

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29

Deep Dives

Research for members
The Additive Alliance® opens up the best of Fraunhofer IAPT for the AM community to access – covering everything from oneto-one discussions with experts, specialists and users through to training sessions and demand-based research. Every year, thisprocess also results in three Deep Dives, each examining one AM-related subject. The members of the Additive Alliance® vote todecide which topics our researchers will focus on. Fraunhofer IAPT carries out the studies and shares the results exclusively withmembers of the Additive Alliance® in Deep Dives in the Member Area.

Making production more sustainable
Deep Dives 2023

Reducing carbon emissions with Directed Energy Deposition (DED)
HELMHOLTZ, Johannes and Maximilian VOGT,
2023. Artificial Intelligence in additive production:
applications and opportunities. In: Additive Alliance. Hamburg, 2023. Hamburg: Fraunhofer IAPT.
HERMANS, Lennard and Lennart WAALKES, 2023.
Metal SLS – a new alternative for LPBF? In: Additive
Alliance. Hamburg, 2023. Hamburg: Fraunhofer IAPT.

Industrial manufacturing is a major contributor to rising global carbon emissions. Metal-based additive manufacturing technologies such as Directed Energy Deposition (DED) open up a resource-friendly, energy-efficient alternative to conventional production. Additive manufacturing reduces material waste, makes it possible to execute energy-saving concepts in lightweight construction and, by keeping production local, eliminates the carbon emissions that result from long journeys.
Additive manufacturing also reduces the carbon emissions of products throughout their life cycle. But how do we achievea successful transition to more sustainable production methods?

LAU, Robert and Hannes ZAPF, 2023. Sustainability
in AM – Data generation and evaluation using
standardized methods. In: Additive Alliance.
Hamburg, 2023. Hamburg: Fraunhofer IAPT.

Focus on success factors
The process starts by gaining a better understanding of thespecific factors affecting the consumption of resources andenergy. Analysing any data that is available makes it possible
to determine whether future optimisations will be successful –however, the stock of data available for AM processes
in particular has been poor to date.
As one of last year’s three Deep Dives, the members of theAdditive Alliance® chose a subject that focuses on investigating
DED processes. The Deep Dive provides an overview of the life
cycle assessment (LCA) methods as well as a presentation ofmaterial and process data, an impact analysis and a comparison with conventional manufacturing. For members of theAdditive Alliance®, the Deep Dive is paving the way for moresustainable production with DED.

30

Key content of the Deep Dives
Life cycle assessment methods
Data on material processingand DED manufacturing
Impact analysis and comparison
with conventional manufacturing

The Deep Dive is available for members of
the Additive Alliance® to download in theMember Area.

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Partnerships

Partnerships
Fraunhofer partnerships
Fraunhofer Group for Production
Fraunhofer IAPT is a member of the Fraunhofer Group for Production (www.produktion.
fraunhofer.de), a collaborative grouping of 11 Fraunhofer institutes and research units. Founded
in 1988, the purpose of the group is to engage in joint research and development with a close
relationship to production. By using the latest findings from production management, engineering and IT, the group offers a range of services that cover the entire product life cycle or value
chain. It ensures that research and industry are closely networked, taking an interdisciplinary
approach. The group provides German and international customers with comprehensive systemsolutions by combining the wide-ranging skills and experience offered by the individual members. In this way, they make companies fit for the production environments of the future. As a
key member of the group, Fraunhofer IAPT provides it with expertise in the fields of industrial
and autonomous solutions for additive manufacturing technologies.

Patents granted

Fraunhofer-Gesellschaft Competence Field Additive Manufacturing
The Fraunhofer Competence Field Additive Manufacturing (www.additiv.fraunhofer.de) integrates 19 institutes across Germany, meaning it reproduces the entire additive manufacturing
process chain. This includes the development, application and implementation of additive manufacturing methods and processes. Its services are aimed at sectors such as handling and assembly, medical engineering, mobility, microsystems engineering and toolmaking, but can also be
used across industries. Since it was founded in 2018, Fraunhofer IAPT has been a member of the
Fraunhofer Competence Field Additive Manufacturing and contributes to joint contract research
projects and trade show appearances.

2023

Research partnerships

Resorbable implants with
controlled degradation
DE102021103786A1
Inventor: Janzen, Kevin; Imgrund, Philipp;
Buresch, Hendrik; Ebel, Thomas

There were also six patent registrations
and two invention disclosures.

32

University Medical Center Hamburg-Eppendorf
The Life Science department at Fraunhofer IAPT works on various areas of research in conjunction with the Department of Oral and Maxillofacial Surgery (MKG) at the University Medical Center Hamburg-Eppendorf (UKE). The background to this partnership is the integrationof additive manufacturing in the clinical workflow and its further development for specificapplications.
The various focal points of the research are coordinated at the UKE by Prof. Ralf Smeets, whoheads the Regenerative Orofacial Medicine division in the MKG. Prof. Smeets also works in anadvisory capacity at Fraunhofer IAPT, with the aim of translating the ideas of medical practitioners into the language of engineers. The joint research activities range from digital image
capture and processing to the application of AI for reconstructing medical anatomies, as well as
the development of new additive processes and materials. Working together with the Helmut
Schmidt University, the DigiMed project (grant number ERDF/REACT-EU 51164122) was successfully concluded in 2023 and highlighted a new digital and physical production chain for optimised patient care. Further cooperative projects focusing on the development of smart wounddressings and 3D-printed facial prostheses are planned for 2024.

33

partnerships

partnerships

Helmut Schmidt University/University of the Federal Armed Forces Hamburg (HSU/UniBw H)
The Professorship Computer Science in Engineering at Helmut Schmidt University Hamburg (HSU)(www.hsu-hh.de) engages in a close strategic partnership with Fraunhofer IAPT. The department
has more than 20 employees and is led by Institute Director Prof. Oliver Niggemann. It offers abroad range of expertise relating to methods of machine learning (ML) and artificial intelligence(AI) for cyber-physical production systems. The joint research activities combine the skills offeredby the two research units and promote digitalisation in additive manufacturing. Interdisciplinary
projects support active knowledge transfer between employees at Fraunhofer IAPT and HSU.

MN3D
Fraunhofer IAPT is a member of the steering committee in MN3D, the maritime network for 3D
printing. Its members aim to unlock the potential of additive manufacturing in shipbuilding andother maritime applications, as well as initiate joint research and development projects in thisarea. The MN3D network operates in close collaboration with the Maritime Cluster Northern
Germany (MCN).

Industry partnerships
The collaboration aims to increasingly explore joint projects in the context of HSU and other
Hamburg partners in order to strengthen the local research landscape.

Networks

Sponsored byAdditive Alliance®
The Additive Alliance® is the industrial research network for additive manufacturing at the Fraunhofer-Gesellschaft, with Fraunhofer IAPT acting as its organiser. Within the Additive Alliance®,
Fraunhofer IAPT stages events and teaches companies about the opportunities presented by additive manufacturing. The concept combines talks and training sessions given by Fraunhofer IAPT
with user reports and networking opportunities. 2021 and 2022 each saw two events take place.
In addition, researchers at Fraunhofer IAPT have conducted research into three of the challenges
presented by additive manufacturing; these were chosen by the members. The resulting Deep
Dives are available exclusively to members of the Additive Alliance® in the first year after publication. Mesago Messe Frankfurt, organiser of Formnext, has been the official sponsor and collaboration partner of the Additive Alliance® and of Fraunhofer IAPT since 2020.
3D-Druck Nord
3D-Druck Nord is the 3D printing network for the Hamburg Metropolitan Region and aims to promote the development of additive manufacturing in northern Germany. In 2018, the network wasfounded as 3DMRHH by the Hamburg Chamber of Commerce. Following a hiatus due to the pandemic, it returned in August 2021 with a new name and a new administration, but the same goal.
Fraunhofer IAPT works together with Hamburg-based partners Fehrmann Alloys, Deutsches Elektronen-Synchrotron (DESY), Hamburg Chamber of Commerce, Hamburg Chamber of Craft Trades
and the Industry Association of Hamburg (IVH), plus Lübeck Chamber of Industry and Commerce,
Technikzentrum Lübeck (TZL) and Fraunhofer IMTE. Its goal is to network research and business in the AM sector in northern Germany, facilitate dialogue and increase the visibility of the
Hamburg Metropolitan Region as a leading international hub of expertise in the field of additive
manufacturing.
Mobility goes Additive
As a founding member, Fraunhofer IAPT has been actively involved in the Mobility goes Additivee. V. network for over five years. Originating from an initiative by Deutsche Bahn, the network
aims to industrialize additive manufacturing, especially for the mobility sector. Fraunhofer IAPT
leads the »Education« working group, probably the most significant international 3D printing
network, and develops concepts for technology-related training and education. Additionally,
Fraunhofer IAPT supports the approval of additively manufactured components for rail transport
and the development of new materials, such as fire-resistant ones, in the »Approval« and »Materials« working groups. Since 2019, Fraunhofer IAPT has also been active in the newly formed sister
network »Medical goes Additive,« striving to identify and implement innovative medical applications for 3D printing.

34

3D Spark GmbH
3D Spark (www.3DSpark.de) was founded in June 2021 by three former employees of Fraunhofer IAPT. The company develops and markets software for identifying and quantifying costsavings in companies’ production processes. To this end, it has analysed CAD data, ERP data
and technical drawings using AI-powered algorithms and identified the exact componentsthat 3D printing can make more cost-effectively than methods that have been used previously.
Fraunhofer IAPT and 3D Spark are collaborating in the field of software-based part screening inorder to open up new applications for 3D printing and give customers the best possible advice
when it comes to introducing 3D printing.
AMPOWER GmbH & Co. KG
For many years, Fraunhofer IAPT has maintained a close partnership with Hamburg-based
consulting firm AMPOWER (https://am-power.de). As part of a joint training concept, thetwo combine their expertise in the field of binder jetting and offer a hands-on workshop that
benefits customers by incorporating not only AMPOWER’s comprehensive knowledge of thetechnology and market, but also Fraunhofer IAPT’s knowledge of processes and machinery. In
addition, joint projects are undertaken to develop materials including process design guidelines
and qualification strategies.
Fraunhofer Industrial Application Center Quantum Computing Hamburg (Fraunhofer
IQHH)
In 2023, Fraunhofer IAPT joined the Fraunhofer institutes ITMP, IAP and CML in founding the
Fraunhofer Industrial Application Center Quantum Computing Hamburg (Fraunhofer IQHH) in
the form of a virtual organisation. The four partners are working together to develop resources
and capacities in the new field of quantum technology.

IQHH

Quantum computers can rapidly make calculations that conventional computers would takeyears to complete. Their capacity is redefining what it is possible to compute, and they are
opening up huge opportunities for researchers and businesses to design and optimise products and production processes on the basis of innovative materials and logistics processes andsystems. Fraunhofer IQHH represents a unique, applied source of skills and knowledge for the
Hamburg economy.
Fraunhofer IQHH is also working with other networks, such as the Hamburg Quantum Innovation Capital (hqic) and the Fraunhofer Competence Network Quantum Computing. This allows
the IQHH application centre to access the extensive knowledge and expertise offered by the 12
Fraunhofer institutes in the Fraunhofer Competence Network Quantum Computing whenevernecessary. As part of a national partnership with IBM, Fraunhofer has also obtained preferential
access to IBM Quantum System One, which is currently the only quantum computer that can beused with secure IP access.

35

Publishing notes

Contact

Publishing notes
Published by
Fraunhofer Research Institution for Additive Manufacturing
Technologies IAPT
Am Schleusengraben 1421029 Hamburg-Bergedorf
Germany
Phone +49 40 484010-500
www.iapt.fraunhofer.de
info@iapt.fraunhofer.de
is a legally non-independent research institution of the Fraunhofer-Gesellschaft zur Förderung der angewandten Forschunge. V.
Hansastrasse 27 c
80686 München, Germany
www.fraunhofer.de
info@zv.fraunhofer.de
Editorial teamTatjana Dems
Layout and typesetting
Catharina Clemens
Equality and gender
In certain cases, our wording does not use masculine andfeminine forms of speech at the same time. This is to ensure
better readability. However, this does not imply any discrimination towards the female gender; rather, it is intended to be agender-neutral approach that aims to simplify the language.
Copyright
All rights reserved. Reproduction or distribution requires
the approval of the editorial team.
© Fraunhofer IAPT, 2024

Image credits
Cover image: © Fraunhofer IAPT
Pages 4, 6, 9, 11, 14, 15, 18, 20, 21, 22, 23, 27, 28, 29© Fraunhofer IAPT
Page 7, bottom image: ilyasov
Page 8, Maxim
Page 12,Top-left image: k_e_n–stock.adobe.com
Top-right image: metamorworks–stock.adobe.com
Bottom-left image: metamorworks–stock.adobe.com
Bottom-right image: ipopba–stock.adobe.com
Page 19, top image: EIT Manufacturing and agefis
Page 23, top image: kobuagency
Page 24, top image: Mobility goes Additive e.V.
Page 24, bottom image: Siemens AG
Page 25, top image: Coherent Inc.
Page 23, centre image: toolcraft AG
Page 23, bottom image: EOS GmbH
Page 26, onephoto
Page 30, fizkes
Sources[1] E uropean Commission, Directorate-General for Researchand Innovation, Breque, M., De Nul, L., Petridis, A., Industry
5.0: towards a sustainable, human-centric and resilient
European industry, page 14[2] Nachhaltig produzieren und konsumieren (bundesregierung.de)https://www.bundesregierung.de/breg-de/themen/nachhaltigkeitspolitik/produzieren-konsumieren-181666

Contact
Fraunhofer Research Institution for
Additive Manufacturing Technologies IAPT		

Am Schleusengraben 14

		21029 Hamburg-Bergedorf[3] m edia-version--am-village-2023.pdf (europa.eu)
https://eda.europa.eu/docs/default-source/documents/
media-version--am-village-2023.pdf

		Germany		+49 40 484010-500		info@iapt.fraunhofer.de		www.iapt.fraunhofer.de		www.linkedin.com/company/fraunhofer-iapt
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