Platform for powder bed fusion of plastics using laser beam

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The subject of the project is a platform system for powder bed fusion of plastics using a laser beam (PBF-LB/P), which enables basic research in the field of process technology for additive manufacturing processes. To be able to adapt the platform to different research questions, it is based on an adaptive, modular concept with the main components: optics module, process chamber, and control unit.The adaptive optics module includes a CO2 laser and a three-axis optical beam deflection unit. The innovative process strategies that become feasible with this technology will contribute to increasing the economic efficiency of the PBF-LB/P process by enabling a reduction in process time.In addition to standard features, the process chamber includes an adaptable and multi-stage coating system, a reduction of the build volume, and integrated high-speed and thermographic cameras. The system is able to process plastics with a melting point of up to 300 °C. These system features are essential for an efficient qualification and development of new powder materials, the establishment of a closed powder cycle, and for fundamental scientific investigations to increase the reproducibility of part properties. The control unit and the corresponding software must be considered closely with the hardware components already described. The control unit is designed to operate openly, to enable precise process monitoring. This opens up new perspectives for qualifying novel plastic powders during PBF-LB/P, for the detection and prevention of component defects, or for providing predictive values for part properties without the need for post-process material test. The beam source, the beam deflection unit, and the corresponding components can be controlled and adapted independently of the manufacturer.Thus, the PBF-LB/P platform offers the possibility to deepen process research and material development in the field of PBF-LB/P along the entire process chain and to detect and exploit potentials for increasing process understanding, process speed, process robustness and sustainability. In order to be able to conduct independent research in the field of PBF-LB/P and thereby generate new knowledge in the research areas of process and materials research outlined in the application, the funding of the PBF-LB/P platform is of fundamental importance.