MADE-3D: Multi-Material Design using 3D Printing

添加制造(AM)具有补充传统制造工艺的经济潜力，特别是在复杂、多材料(MM)部件的生产中。为了充分发挥优化轻量化结构的优势，通常需要使用具有不同物理性能的多种材料。然而，由于不同材料的残余应力、裂纹或热膨胀率，来自传统工艺的多种材料组合不能转移到AM。此外，几何形状和位置公差以及粉末废物、后处理废物和部件本身的回收战略尚未确定。基于3D打印工艺PBF-LB和DED，该项目的目标是设计可加工的多材料优化合金的并行工程，开发针对载荷情况和拓扑优化的特定模拟的多材料结构设计概念，以及广泛的工艺适应。合金和工艺开发将得到先进的集成计算材料工程方法的帮助，这些方法通过机器/主动学习将热力学、微结构和工艺模拟结合在一起，从而缩短材料开发周期。对于散装和粉状材料，通过创新概念回收多材料组件将促进多材料添加剂制造的可持续性。这一适应将导致工艺可靠性和速度的提高，使MM制造在AM中推广到整个行业。该联盟将广泛的国际专业知识带到谈判桌上，从材料研究和数字化到多材料部件的制造。它由添加剂制造领域的初创企业、研究机构和市场领导者组成。工业终端用户通过特定的用例覆盖汽车、航空航天和航空应用。

Additive manufacturing (AM) has the economic potential to complement conventional manufacturing processes, especially in the production of complex, multi-material (MM) components. To exploit the full benefits of optimized lightweight structures, it is usually required to use multi-materials with different physical properties. Still, multi-material combinations from conventional processes are not transferable to AM, due to residual stresses, cracks or thermal expansion rates of the different materials. Furthermore, geometric shape and position tolerances, as well as recycling strategies for powder waste, post-processed waste and the component itself are not yet defined. Based on the 3D printing processes PBF-LB and DED, this project aims at the concurrent engineering of designing processable multi-material optimized alloys, development of design concepts for multi-material structures with specific simulations for load cases and topology optimizations, and an extensive process adaption. Alloy and process development will be aided by advanced integrated computational material engineering approaches that combine thermodynamics, microstructure, and process simulations through machine-/active learning, resulting in shorter material development cycles. For bulk and powder materials, recycling of multimaterial components via innovative concepts will promote the sustainability of multi-material additive manufacturing. This adaption will lead to increased process reliability and speed, enabling the dissemination of MM manufacturing in AM for the entire industry. The consortium brings a wide range of international expertise to the table, from materials research and digitization to the manufacture of multi-material components. It consists of startups, research institutions and market leaders in additive manufacturing. Industrial endusers cover automotive, aerospace and aeronautic applications with specific use cases.