DDMC2016

Berlin, March 16 - 17, 2016

Proceedings

DDMC 20163rd Fraunhofer Direct Digital Manufacturing Conference

Organized by the Fraunhofer Additive Manufacturing Alliance, the bi-annual Direct Digital Manufacturing Conference brings together researchers, educators and practitioners from around the world. The conference covers the entire range of topics in additive manufacturing, starting with methodologies, design and simulation,right up to more application-specific topics, e.g. from the realm of medical engineering and electronics.

PREFACE

DDMC 2016 again featured a powerful technical program with 6 keynotes, 54 presentations in 16 sessions and 12 posters. DDMC 2016 was a truly immersive experience for the well over 150 conference delegates participating. For the conference proceedings the papers are structured according to the 15 conference sessions, each presenting the current state of the art in additive manufacturing.I would like to take this opportunity to thank all the authors for their contributions as well as the members of the scientific committee for the time and effortthey put in the double-blind review process, thus ensuring the excellent quality of presentations. My congratulations go to the winners of the Best Paper Award (Chris Bailey, Stoyan Stoyanov, Tim Tilford and Georgios Tourloukis from the University of Greenwich/ UK for their paper on “Modelling Methodologies for Quality Assessment of 3D Inkjet Printed Electronic Products”) and Best Poster Award (Łukasz Żrodowski, Bartłomiej Wysocki et al from the Warsaw University of Technology/ Poland for their work on “The Novel Scanning Strategy For Fabrication Metallic Glasses By Selective Laser Melting”).

Last not least please be reminded that the next DDMC conference will be taking place March 14-15, 2018 in Berlin. I look forward to seeing you there!

Sincerely,Dr.-Ing. Bernhard MuellerDDMC 2016 CONFERENCE CHAIRSpokesman Fraunhofer Additive Manufacturing Alliance

IMPRINT

Contact:Dr.-Ing. Bernhard MuellerFraunhofer Additive Manufacturing Alliancec/o Fraunhofer Institute for Machine Tools and Forming Technology IWUNoethnitzer Straße 4401187 DresdenGermanyPhone +49 351 4772-2136Fax +49 351 4772-2303E-Mail info@generativ.fraunhofer.deURL http://www.generativ.fraunhofer.de

Bibliographic information published by Die Deutsche NationalbibliothekDie Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliografic data is available in the Internet at www.dnb.de.

ISBN (E-Book): 978-3-8396-1001-5

© by Fraunhofer Verlag, 2016Fraunhofer Information-Centre for Regional Planning and Building Construction IRBP.O. Box 80 04 69, 70504 StuttgartNobelstrasse 12, 70569 StuttgartPhone 0711 970-2500Fax 0711 970-2508E-Mail verlag@fraunhofer.deURL http://verlag.fraunhofer.de

All rights reserved; no part of this publication may be translated, reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the written permission of the publisher.

Many of the designations used by manufacturers and sellers to distinguish their products are claimed as trademarks. The quotation of those designations in whatever way does not imply the conclusion that the use of those designations is legal without the consent of the owner of the trademark.

CONTENT

TABLE OF CONTENTS

Session 1.1: Novel Applications

Additive Manufacturing of Architectural Façade Elements 21Sven PfeifferTU Berlin, Institute for Architecture, Germany

Dispenser and Aerosoljet Printed Electrical Functionalities 25 Ines Dani1, Lukas Stepien1, Aljoscha Roch1, Christoph Leyens1,2

1Fraunhofer IWS, Germany; 2Technische Universität Dresden

3D Printing Embedded Sensors Using Solid State Welding 29Mark Ira Norfolk1, Justin Wenning1, Adam Hehr2, Hilary Johnson1

1Fabrisonic LLC, Columbus, USA; 2The Ohio State University, Columbus, USA

Session 1.2: Design

Aerospace Case Study on Topology Optimization for Additive Manufacturing 37Michael Süß1, Christine Schöne2, Ralph Stelzer2, Burghardt Klöden1, Alexander Kirchner1, Thomas Weißgärber1, Bernd Kieback1,2

1Fraunhofer IFAM Institutsteil Dresden, Germany; 2Technische Universität Dresden, Germany

Development of Light Weight Lattice Structure Using 3D-printing 43Umesh Gandhi, Recep Gorguluarslan, Yuyang SongToyota Technical Center, United States of America

Session 1.3: Powder

From Powders to Metal Parts Through Selective Laser Melting: Comparison of Several Commercial Al-12Si Alloy Powders 53Olivier Dellea1, Philippe Berne1, Maria Averyanova2, Romain Soulas1, Pascal Revirand1, Pascal Fugier1, François Tardif1

1CEA LITEN, France; 23D SYSTEMS France

Effects on Properties of Metal Powders for Laser Beam Melting Along the Powder Process Chain 59Max Lutter-Günther, Christian Seidel, Gunther ReinhartFraunhofer IWU, Germany

About the Influence of Powder Properties at the Selective Laser Melting Process 67Sebastian Matthes, Robert Kahlenberg, Christian Straube, Simon Jahnifw Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

Session 2.1: EBM

Numerical Investigations of Selective Electron Beam Melting on the Powder Scale 75 Matthias Markl, Andreas Bauereiß, Abha Rai, Carolin KörnerChair of Metals Science and Technology, Friedrich-Alexander Universität Erlangen-Nürnberg, Germany

Influence of Scanning Strategy on Properties of Titaniumalumindes Produced by Selective Electron Beam Melting 81Vera Juechter1, Carolin Körner2

1WTM, University of Erlangen-Nürnberg, Germany; 2WTM, University of Erlangen-Nürnberg, Germany

Process and Quality Supervision for EBM Production Applications 87Ulric Ljungblad, Johan Backlund, Patrik OhldinArcam AB, Sweden

Processing Specifics in Electron Beam Melting of TiAl 93Burghardt Kloeden1, Alexander Kirchner1, Thomas Weißgärber1, Bernd Kieback1, Sara Biamino2, Giorgio Baudana2

1Fraunhofer IFAM, Dresden, Germany; 2Politecnico di Torino, Italy

Session 2.2: Simulation

Comparison of Approaches for Structural Simulation of Additively Manufactured Metal Parts Based on Simufact.welding 101Hendrik Schafstall1, Pavel Khazan1, Patrick Mehmert1, Thomas Töppel2, Richard Kordaß2

1simufact engineering GmbH, Germany; 2Fraunhofer-Institute for Machine Tools and Forming Technology IWU, Germany

Pre-compensation of Warpage for Additive Manufacturing 109Christoph Schmutzler1, Fabian Bayerlein1, Stephan Janson1, Christian Seidel1,2, Michael F. Zaeh1

1Technical University Munich, Institute for Machine Tools and Industrial Management, Germany; 2Fraunhofer IWU, Germany

Design Against Distortion of SLM Parts Based on Simplified Numerical Modelling Methodologies 117Pedro Alvarez, Joseba Ecenarro, Iñaki Setien, Maria San Sebastian, Alberto EcheverriaIK4-LORTEK, Spain

Simulation Aided Manufacturing: Scanning Strategies for Low Distortion in Laser Beam Melting Processes 123Nils Keller, John Schlasche, Hongxiao Xu, Vasily PloshikhinAirbus Endowed Chair for Integrative Simulation and Engineering of Materials and Processes (ISEMP), University of Bremen, Germany

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

Session 2.3: Quality

Improving Part Quality in LBM Processes by Geometry Based Scanparameter Adaption 131Hongxiao Xu1, Vasily Ploshikhin1, Alexander Kulikov2, Ruslan Loginov2, Benjamin Günther3

1University of Bremen, Germany; 2Neue Materialien Bayreuth GmbH, Germany; 3Concept Laser GmbH, Germany

Surface Modification by Laser Re-melting of Parts Produced by Electron Beam Melting 137Marcin Madeja, Jarosław Kurzac, Edward ChlebusWrocław University of Technology, Poland

Influence of Ambient Conditions on the Laser Based Powder Bed Fusion Process 143Simon Jahn, Robert Kahlenberg, Christian StraubeGünter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany

Microstructure and Mechanical Properties of Inconel 718 for the Manufacture of Aircraft Parts by Selective Laser Melting 149Tomasz Kurzynowski, Jaroslaw Kurzac, Konrad Gruber, Bogumila Kuznicka, Edward ChlebusWroclaw University of Technology, Poland

Session 3.1: Novel Materials

Fabrication of Cu-Al-Ni-Mn Shape-Memory Parts by Selective Laser Melting 159Tobias Gustmann1, A. Neves2, U. Kühn1, P. Gargarella2, C. S. Kiminami2, C. Bolfarini2, J. Eckert1, S. Pauly1

1IFW Dresden, Germany; 2UFSCar, Brazil

SLM Processing of 14 Ni (200 Grade) Maraging Steel 165Philipp Stoll1, Adriaan Spierings1, Konrad Wegener2, Stefan Polster3, Mathias Gebauer3

1inspire AG, Switzerland; 2IWF - Institut für Werkzeugmaschinen und Fertigung der ETH Zürich, Switzerland; 3Fraunhofer IWU, Germany

Process Parameters for Selective Laser Melting of AgCu7 171Harald Rieper1, Andreas Gebhardt2, Brent Stucker1

1University of Louisville, USA; 2Aachen University of Applied Sciences, Germany

3D-printing Using Conditioned Miscanthus – Application for Special Packaging 177Diana Klemm, Henning Zeidler, Wolfgang Meyer, Gunther GlowaBECKMANN-INSTITUT für Technologieentwicklung e. V., Germany

Session 3.2: Process Chains

Investigation and Assessment of a Laser Additive Manufacturing based Process Chain by the example of an Injection Mold 187Fritz Klocke1, Reinhart Poprawe2, Robert Schmitt1, Andres Gasser2, Kristian Arntz1, Markus Grosse Böckmann1, Nils Klingbeil1, Johannes Kerkhoff1, Thomas Vollmer1, Maximilian Wegener1, Moritz Alkhayat2

1Fraunhofer IPT, Germany; 2Fraunhofer ILT, Germany

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

Process Analysis and Optimization of Current AM Technologies on the Example of Laser Sintering 193Michael ten Hompel1, Christian Prasse2, Mathias Rotgeri2, Eric Klemp3

1Chair of Materials Handling and Warehousing, TU Dortmund, Germany; 2Fraunhofer Institute for Material Flow and Logistics, Germany; 3Direct Manufacturing Research Center, Universität Paderborn, Germany

Influencing Factors on Quality of Titanium Components Manufactured by Laser Melting 199Simon Jahn1, Christian Straube1, Felix Gemse1, Vanessa Seyda2, Dirk Herzog2, Claus Emmelmann2

1Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH, Germany; 2Technische Universität Hamburg-Harburg, iLAS Institut für Laser- und Anlagensystemtechnik, Germany

Process Parameter Development for Industrial Hybrid Machine 205Benjamin Bax, Lukas Löber, Holger Perfahl, Marcel Pawlik, David Albert, Martin Reisacher, Patrick DiederichSauer GmbH (DMG MORI), Germany

Session 3.3: Quality Methods

Quality Control Process for Additive Manufactured Parts 213Tobias Grimm1, Georg Wiora2, Gerd Witt1

1Institute of Product Engineering, Manufacturing Technology, University of Duisburg-Essen, Duisburg, Germany; 2NanoFocus AG, Oberhausen, Germany

Topology Examination for Additive Manufactured Aluminum Components 219Rene Bastian Lippert, Roland LachmayerLeibniz Universität Hannover, Germany

Practical Powder Analysis for Metal Powder Bed Based AM 225Claus Aumund-Kopp, Daniela Zibelius, Juan IsazaFraunhofer IFAM, Germany

In-Situ Surface Roughness Measurement of Laser Beam Melted Parts – a Feasibility Study of Layer Image Analysis 231Joschka zur Jacobsmühlen1, Stefan Kleszczynski2, Alexander Ladewig3, Gerd Witt2, Dorit Merhof1

1RWTH Aachen University, Germany; 2University of Duisburg-Essen, Duisburg, Germany; 3MTU Aero Engines AG, Munich, Germany

Session 4.1: Ceramics

Lithography-based Ceramic Manufacturing: Layer-by-layer to Dense and Precise Ceramic Parts 241Martin Schwentenwein, Johannes HomaLithoz GmbH, Austria

Equipment, Material and Processes for UV-DLP-based Additive Manufacturing of Two-component Ceramic Green Bodies and Dense Structures 245Patrick Springer1, Eric Schwarzer2, Oliver Refle1, Hans-Jürgen Richter2

1Fraunhofer IPA, Stuttgart, Germany; 2Fraunhofer IKTS, Dresden, Germany

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

Development of Photo-curable Ceramic Suspensions Usable for Additive Manufacturing of Components 255Eric Schwarzer, Uwe Scheithauer, Matthias Ahlhelm, Anja Härtel, Hans-Jürgen Richter, Tassilo MoritzFraunhofer IKTS, Germany

Multi-material Approach to Integrate Ceramic Boxed Temperature-sensitive Components in Laser Beam Melted Structures for Bio and Other Applications 261Holger Lausch1, Thomas Töppel2, Romy Petters2, Bernd Gronde1, Mathias Herrmann1, Kerstin Funke2

1Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden/Hermsdorf, Germany; 2Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz/Dresden,Germany

Session 4.2: Process Innovations

Selective Electron Beam Melting of the Single Crystalline Nickel-based Superalloy CMSX-4 273Carolin Körner, Markus Ramsperger, Abha RaiUniversity of Erlangen-Nuremberg, Germany

Correlation Analysis of Different Building Parameters on the Part Properties of Parts Built by Simultaneous Laser Beam Melting of Polymers 279Tobias Laumer1,2,3, Thomas Stichel1,2, Michael Schmidt1,2,4

1Bayerisches Laserzentrum, Erlangen, Germany; 2CRC 814 Additive Fertigung, Friedrich-Alexander-University, Erlangen-Nürnberg, Germany; 3SAOT Erlangen Graduate School in Advanced Optical Technologies, Erlangen, Germany; 4LPT Institute of Photonic Technologies, Friedrich-Alexander-University, Erlangen-Nürnberg, Germany

Multi Material Processing in Laser Beam Melting 285Christine Anstätt1, Christian Seidel1,2, Gunter Reinhart1,2

1Faunhofer IWU, Germany; 2Company iwb, Munich, Germany

Aluminium Matrix Nano Composites by DMLS: Effect of the Nanoparticles on the Microstructure and Mechanical Properties. 291Alberta Aversa1, Giulio Marchese1, Diego Manfredi2, Flaviana Calignano2, Elisa Ambrosio2, Sara Biamino1, Paolo Fino1, Matteo Pavese1, Massimo Lorusso2

1Politecnico di Torino, Italy; 2Istituto Italiano di Tecnologia, Italy

Session 4.3: Polymer

New Materials for Laser Sintering: Processing conditions of Polyethylene and Polyoxymethylene 301Andreas Wegner1,21University of Duisburg-Essen, Germany; 2AM Polymer Research UG

Thiol-ene Reactions in Stereolithography, an Alternative to Epoxy and Acrylic Resins? 307Holger Leonards1, Marlene Runte1, Andreas Hoffmann1,2, Sascha Engelhardt1,2, Martin Wehner1, Arnold Gillner1

1Fraunhofer Institute for Laser Technology, Aachen; 2Chair for Laser Technology, RWTH Aachen University

Optimization Considerations for FDM 3D Printing of Fiber Reinforced Polymeric Materials 311Uwe Popp, Brando OkoloIndmatec GmbH, Germany

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed

1 ISBN 978-3-8396-1001-5 © Fraunhofer / DDMC 2016

March 2016, Berlin / GERwww.ddmc-fraunhofer.de

Additive Manufacturing of Architectural Façade Elements

Sven Pfeiffer

Technical University of Berlin, Berlin, Germany

s.pfeiffer@tu-berlin.de, +49 30 314 25255

Abstract

The research paper focuses on the use of additive manufacturing for the design and production of architectural

façade elements. Architecture is often referred to as protection against rain, heat and wind. An alternative view,

inspired by traditional buildings and forced by climate change predictions, however, shows the importance for

architecture to engage with the climate in a more substantial way. As the current tendency to achieve energy-

efficiency in buildings by thermal composite insulation systems and high-tech applications is being increasingly

criticized for being unsustainable, the demand for meaningful alternatives rises, of which the solution lies less in

generic, technological development, but rather in dealing in an intelligent way with specific and regional conditions.

As with additive manufacturing it is not necessary to produce a large number of equal components, building

elements as “series of single parts” could be thought of, which are optimized for the climatic micro-context in which

they are used. In the presented research-by design project architects in collaboration with external partners explore

the functional and aesthetic potentials of additive manufacturing processes for the design of 1:1 building elements

which integrate climatic functions. Inspired by architectural precedents and natural systems, ventilation, channelling

flows, evaporative cooling and/or insulation functions are integrated in building elements with a unique functionality

and aesthetic unprecedented in traditional manufacturing processes.

1 Context

Due to global challenges of climate change, dwindling

resources and an accelerated urbanization, the planning

and fabrication processes in the building sector face an

increasing transformation and research pressure. The

main problem of the building industry (10% of BIP) is

its resource inefficiency. The buildings sector is the

largest energy-consuming sector, accounting for over

one-third of final energy consumption globally and an

equally important source of carbon dioxide (CO2)

emissions [1]. Many traditional building materials have

a high environmental footprint and building processes

use a wide array of technologies which are rarely

integrated. The reasons lie in the size and economic

pressures on the one-off product “building” and its

immobility, which put borders on a further

automatization of large-scale fabrication processes. The

traditionally specialized functions of building elements

such as bricks or tiles inevitably raise the costs and

resources for on-site assembly processes (e.g. masonry

construction) and frequently involve different stages in

their production. In addition to this, sub-systems with

different functions and life-spans (e.g. construction and

installation) have to be integrated. A sustainable

transformation of the building sector will have to

overcome these problems posed by traditional

fabrication processes.

2 Additive Fabrication in Architectural

design and the Building Industry

Whereas additive manufacturing processes have been

widely introduced in high-tech sectors such as airplane

and automotive industries [2], the building sector is in

many areas characterized by traditional production

methods. In building, 3D printing is not commonly

encountered due to issues of cost and of scale. Until

recently, additive fabrication has been mainly used in

architecture to produce scaled representations of the

actual design. The shift from a scale model to the 1:1-

Scale of a building includes a substantial examination of

the physical properties of printable materials and the

lifetime of printed building parts. Nevertheless, as

technology progresses, additive manufacturing for

architectonic applications with small numbers of

elements could be economically feasible as tooling and

storage costs disappear. Whereas production costs for

one cubic meter in stereolithography and laser sintering

lie at over 30K €, other processes such as FDM (Fused

Deposition Modeling) ranges at costs of 2000 €/m3 [3].

Since the mid-nineties a few universities and companies

have started to attempt to apply additive fabrication in

architecture or construction. Most research goes into

various FDM processes, by which a building material is

deposited in layers. The extrusion head is moved in

relation to the construction platform. The shape of the

element is defined in outline and the enclosed area then

filled in. Different kinds of material can be used with

this method such as plastics, concrete or ceramic paste.

A variation on this system is known as “contour

crafting”[4][5] . In the Contour Crafting process, fixed