ReBi - Resource-efficient component innovation through additive manufacturing processes in the Bavarian and Austrian border region

By using additive manufacturing technology, designers can meet the growing demand for innovative products that meet climate change goals. The layer-based construction method enables the production of components with new geometries and material combinations that could not be realized before. In particular, there is great potential for lightweighting and functional integration, as well as material-related developments such as graded material transitions and improved specific strengths.

Although additive manufacturing technology has completed the paradigm shift from prototype processes to (small) series production, there are still barriers to implementation, especially for small and medium-sized enterprises (SMEs), as they often do not have the necessary manufacturing expertise. In the border region between Bavaria and Austria, there are many SMEs that need support in order to remain competitive and secure jobs.

The aim of the research project is to explore new approaches for materials, processes and product design in order to realize resource-efficient component innovations with the help of additive manufacturing. Finally, the results will be made available to SMEs in the form of a competence center, training courses, consulting and demonstrations.

Project Background

Established research institutions show a constant interest in the advancement of additive manufacturing processes and the associated possibilities in part design and manufacturing processes. The continuous innovation of the processes leads to an increasing amount of data in the respective fields and can be overwhelming for new users. The variety of possibilities offered by additive manufacturing in the field of lightweight construction seems to be unmanageable for non-involved specialist groups and can ultimately lead to reluctance.

The research project is intended to help small and medium-sized companies in particular at this point and to simplify the integration of additive processes in lightweight construction. As a result, locations in the Bavarian-Austrian region should be consolidated and remain competitive with innovative processes.

Project Goal

In summary, the project aims to establish a knowledge management system for small and medium-sized enterprises in the Bavarian-Austrian border region. In order to achieve this goal in the best possible way, the following project objectives are to be achieved in summary:

Realization of a competence center for functionally optimized innovative components using additive manufacturing processes with the provision of consulting and training opportunities.
Provide new approaches for the development and design of sustainable lightweight structures, individualized solutions and digitalization of production, as well as guidelines for economic feasibility studies.
Development of materials, processes and procedures to expand the range of applications for additive manufactured lattice structures. The focus is on both powder-based and wire-based processes using metallic materials to overcome existing geometric and mechanical constraints.
Development of simulation models for the efficient design of components with lattice structures to explore and evaluate the potential of additive manufacturing for structural optimization in terms of stiffness, buckling resistance, strength, energy absorption and load transfer in monolithic and hybrid structures.

Project Schedule

The project is divided into three work packages: The development of fundamentals in design and construction methods for metallic additive processes (WP1), the process and material optimization in the developed processes based on lattice structures (WP2), and the transfer of the scientific results obtained into a knowledge management system, so that SMEs in particular can benefit from them.

The systematic implementation of specific subtasks in the work packages and the associated internal communication between the project participants should generate a comprehensive knowledge archive. This knowledge repository results from the bundling and integration of the competencies of all project partners. Through the exchange of knowledge and experience, best practices can be identified and innovative solutions can be developed.

Innovation

The aim and innovation of the project is to provide a knowledge center for additive manufacturing of metallic materials. SMEs, academic and research institutions, education/training centers and schools, and business support organizations will benefit from the processed information in the areas of materials, design, manufacturing and simulation with a focus on lattice-structured lightweight construction.