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

增材制造（AM）具有补充传统制造工艺的经济潜力，特别是在生产复杂的多材料（MM）部件时。为了充分利用优化的轻量化结构的优势，通常需要使用具有不同物理特性的多种材料。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，以及粉末废料、后处理废料和部件本身的回收策略尚未确定。基于3D打印工艺PBF-LB和DED，该项目旨在设计可加工的多材料优化合金的并行工程，开发多材料结构的设计概念，并对负载情况和拓扑优化进行特定模拟，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、微观结构和工艺模拟结合起来，从而缩短材料开发周期。对于散装和粉末材料，通过创新概念回收多材料组件将促进多材料增材制造的可持续性。这种适应将提高工艺可靠性和速度，使整个行业的AM中MM制造的传播成为可能。该联盟带来了广泛的国际专业知识，从材料研究和数字化到多材料组件的制造。它由增材制造领域的初创公司、研究机构和市场领导者组成。工业最终用户涵盖汽车、航空航天和航空应用，并提供特定的用例。

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.