Innovation in 3D: Laser Powder Bed Fusion

An innovative 3D printing process is breaking down traditional manufacturing boundaries and opening up unimagined possibilities from aerospace to medical technology: laser powder bed fusion (LPBF). In our interview, Tim Lantzsch from the Fraunhofer Institute for Laser Technology ILT explains current applications of this promising additive manufacturing technology.

Mr. Lantzsch, what exactly is laser powder bed fusion and what are the advantages?

Tim Lantzsch: Essentially, it's about melting materials, whether polymer or metal, in powder form layer by layer using a high-precision laser beam to create complex components. This process, which was originally known as selective laser melting, enables us to produce components with complicated internal structures, such as grids or undercuts, which would be impossible or very costly to produce using conventional methods. The precision of the laser enables an unrivalled level of detail and freedom of geometry.

What specific areas of application are there for this technology?

Lantzsch: LPBF is used in a variety of industries, especially where complex components with specific properties are required. One important area is the aerospace industry, where lightweight construction, optimized flow guides and the ability to withstand extreme temperatures are important. Another important field of application is medical technology.

Here, the technology enables the production of customized implants and prostheses, such as hip and knee joints, which are precisely adapted to the anatomical conditions of the patient. This not only improves compatibility and functionality, but also the integration of the implant into the body system.

What about the range of materials and current research approaches in additive manufacturing in general?

Lantzsch: The range of materials in the field of additive manufacturing is constantly expanding. Our aim is to develop materials that are both lighter and more resistant. We are particularly focusing on materials for the medical sector that are highly biocompatible, such as titanium, tantalum, magnesium and zinc.

These materials not only offer the necessary mechanical stability, but also properties that enable optimal integration into the human body. In the area of research and development, we are endeavoring to further improve the processability of these materials and reduce manufacturing costs to make these advanced processes accessible to a wider range of applications.

To what extent does artificial intelligence contribute to the optimization of LPBF?

Lantzsch: Artificial intelligence is playing an increasingly important role in the optimization and automation of the laser powder bed fusion process. On the one hand, AI is used in quality assurance to make quality predictions from the data collected during the printing process. This can reduce the need for manual inspections and increase the reliability of the components produced.

On the other hand, we are working on the development of AI-supported design tools that make it possible to design components fully automatically. These tools not only consider the specific requirements of the component, but also optimize the use of materials and the printing process, resulting in innovative and efficient solutions.

What challenges and developments do you see for the future of laser powder bed fusion and additive manufacturing in general?

Lantzsch: One of the biggest challenges lies in scaling up the process - how we can make it faster, more cost-effective and accessible for a wider range of materials and applications. This also includes the further development of AI technologies to further improve design and quality assurance.

Another important topic is the training and further education of specialists in this field. We need a new generation of engineers and technicians who can realize the full potential of additive manufacturing, from conception to production.