Additive Fertigung in der industriellen Serienproduktion: Bauteilidentifikation und Gestaltung

Additive Manufacturing (AM), often referred to as 3D printing, is developing very dynamically. The technology and its machines are so mature that additive series production of final components is possible. The digital process chain and in particular the freedom of design are the outstanding properties of the process. If these advantages are properly exploited, serial components can be produced economically - despite the still high manufacturing costs - which has already been proven by various applications. However, despite their high potential, the processes are by no means widely established in series production and are only hesitantly adopted by companies. The lack of know-how and expertise in dealing with the technology is named as a major obstacle by the industry. This applies mainly to the identification of suitable components and their production-specific design. In order to determine the reasons for the lack of expertise despite the provision of knowledge, a literature-based analysis of the reasons is carried out. On this basis, tools and transfer methods are developed to support the implementation of additive series production. An orientation scheme based on potential clusters provides assistance in identification, enabling manual identification. In addition, a documentation and evaluation system is provided which ensures efficient cooperation with AM experts and the formation of identification expertise in the company. Design is a key issue for AM, as it requires a radical rethink in comparison to conventional design, so that the full potential of the technology can be exploited. In order to offer a support suitable for the target group, design guideline is being developed consisting of the three elements: process characteristics, design principles and guideline values. The technology transfer and the transfer of the AM tools - with corresponding experience in their handling - is the prerequisite for the formation of AM expertise in the companies. The Experience-based Transfer Model (ETM) is developed for this purpose, taking into account the findings from the literature analysis. The implementation in the transfer projects shows that the developed support tools for identification and design are successfully applied in industrial applications. The ETM promotes an effective AM expertise formation in the company and supports the acceptance of the provided tools, since their suitability for use is experienced directly on the own product. The combination of support tools and transfer methods enables the implementation of additive manufacturing in series production and facilitates access to technology for companies