Rapid Prototyping

Nowadays, a private person often starts a DIY project by heading to the hardware store not refraining from further visits during the work process. The latest developments in the so-called 3D-printers promise a prospective autonomy of the end user, enabling him to produce spare parts on his own. Besides, the actual development of the additive manufacturing from rapid prototyping to rapid manufacturing is facing a significant change in the industry, too. This requires a new way of thinking in the companies due to a shift in the value creation process. This paper shows the current state of development of additive manufacturing, highlights the possible consequences for manufacturing companies and is designed to sensitize the reader with regard to the new influences and opportunities.

For the production of pyrolysis models (wax models), which are used in the process of vacuum differential pressure casting, often silicone molds are used. These casting molds are manufactured by using rapid prototyping solid bodies. However, for the shaping only the outer shell is necessary. So the use of hollow bodies to the material and cost savings is possible. In this paper calculations and topology optimizations are presented at the example of a cylinder.

The increasing complexity of technical components and shorter product life cycles make high demands on the flexibility and the efficiency of production processes. Additive manufacturing processes comply with this requirement profile. So far, these methods particularly in the desktop prototyping and manufacturing are common. The undisputed high potential for individual production of small batches by means of additive manufacturing processes is so far due to the low reproducibility of the manufactured components not been fully utilized in terms of a rapid manufacturing. Especially powder- and beam-based additive manufacturing technologies offer in terms of recoverable component strengths with both metallic and polymeric materials have a promising range of applications. The basic scientific study of this process is the goal of the Collaborative Research Centre 814 Additive Manufacturing (SFB 814). In the following article, aims and initial results from the SFB 814 are shown.

In the automotive industry increasing requirements for quality and an awareness of ever rising costs create significant demands for innovation in both developing and manufacturing. These requirements regarding the final product have to be met by using optimal materials during the development and by using appropriate tooling and machining technologies during the manufacturing process. In producing engines a wide spectrum of materials is used, which in turn are worked upon by a variety of manufacturing technologies. With respect to materials’ technology there is a trend towards developing application specific high performance materials with improved mechanical and/or thermal properties. Production technology then develops innovative and safe manufacturing processes and strategies to be able to apply the new materials.

Incremental sheet forming is a new approach, which offers high flexibility and economic advantages for low number manufacturing of complex sheet metal parts. The forming of the sheet metal is effected by the CNC-controlled movement of a universal, ball-headed punch in combination with a simplified die as a support under the sheet. This enables quick and cost effective adaptation to changes of the product geometry. The process itself can be carried out on any conventional 3-axis milling machine which is refitted with a clamping device for the metal sheet.