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3D Printing Solutions For The Automotive Industry

3D Printing Solutions for the Automotive Industry

SLM Solutions looks back on years of experience in 3D printing solutions for the automotive industry. But what does it take to successfully print automotive parts? And what are the main use cases?

Metal additive manufacturing technology is accelerating industrial development in the automotive sector and offers numerous advantages. On the one hand, scalable on-demand local-for-local supply chains can get products to market faster and reduce costs. On the other hand, additive manufacturing can lead to improved performance and functionality of parts.

Selective laser melting (SLM) can be used primarily to bridge the gap between prototyping and series production. Pioneer and metal additive manufacturing partner SLM Solutions looks back on years of experience in 3D printing solutions for the automotive industry. But what does it take to successfully print automotive parts? And what are the main use cases?

Robust Machines and Material

To successfully print parts, robust and reliable machines are required. SLM Solutions’ SLM 500 offers excellent features for industrial series production in the automotive industry. As the first quad-laser system on the market, the machine is ideally suited for the rapid cost-effective production of large metal parts. The multi-laser overlap strategy with up to four 700 W lasers ensures maximum efficiency. The ability to change the build cylinder minimizes machine downtime, maximizes productivity and reduces cost per part. 

Equally important is the right choice of metal powder. SLM Solutions offers various alloys, for example, aluminium alloys, nickel alloys, and titanium alloys, that ideally fit to the requirements of the automotive industry. Furthermore, SLM Solutions develops new materials and parameters with customers. 

Another technology from SLM is the NXG XII 600. Equipped with 12 overlapping 1 kW lasers and a build envelope of 600x600x600 mm, the machine sets new milestones in terms of productivity, size, reliability and safety, and paves the way to the future of manufacturing. Productivity is further enhanced through variable beam spot, bi-directional recoating, laser balance and an optimized gas flow while a closed environment maximizes operator safety.

One company that has already tested the productivity of the NXG XII 600 is Porsche. The Porsche advanced powertrain engineering department also focuses on large powertrain applications, such as e-drive housings, cylinder blocks, and cylinder heads, to name a few, in additive manufacturing. In a proof of concept with the SLM  NXG XII 600, a complete e-drive housing with an innovative AM design was successfully printed. Porsche sets high quality demands on the part: A permanent magnet motor with 800 V operating voltage delivers up to 205 kW (280 hp). The downstream two-stage transmission is integrated in the same housing and drives the wheels with up to 2,100 N-m of torque. This highly integrated approach is designed for use on the front axle of a sports car.

All the advantages of additive manufacturing have been implemented in this housing, such as topology optimization with lattice structures to reduce the weight, functional integration of cooling channels, higher stiffness and reduced assembly time by the integration of parts as well as improvements in part quality.

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Lightning Fast 3D printing: SLM Solutions Prints E-Drive Housing From Porsche On NXG XII 600

 

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Leading A Sustainable Revolution: Ford And HP Collaborate To Transform 3D Waste Into Auto Parts

Leading A Sustainable Revolution: Ford And HP Collaborate To Transform 3D Waste Into Auto Parts

Ford is teaming up with HP to innovatively reuse spent 3D printed powders and parts, closing the loop and turning them into injection molded vehicle parts – an industry first.

Sustainability is a priority for both iconic companies, which through joint exploration led to this unlikely, earth-friendly solution. The resulting injection molded parts are better for the environment with no compromise in the durability and quality standards Ford and its customers demand.

The recycled materials are being used to manufacture injection-molded fuel-line clips installed first on Super Duty F-250 trucks. The parts have better chemical and moisture resistance than conventional versions, are seven percent lighter and cost 10 percent less. The Ford research team has identified 10 other fuel-line clips on existing vehicles that could benefit from this innovative use of material and are migrating it to future models.

“Finding new ways to work with sustainable materials, reducing waste and leading the development of the circular economy are passions at Ford,” said Debbie Mielewski, Ford technical fellow, Sustainability. “Many companies are finding great uses for 3D printing technologies, but, together with HP, we’re the first to find a high-value application for waste powder that likely would have gone to landfill, transforming it into functional and durable auto parts.”

HP 3D printers are already designed for high efficiency, with systems and structures to minimise the excess material they generate and reuse a greater percentage of the materials put into them. Working with Ford, which uses HP’s 3D printing technology at the company’s Advanced Manufacturing Center, the team created this solution that produces zero waste.

“You get more sustainable manufacturing processes with 3D, but we are always striving to do more, driving our industry forward to find new ways to reduce, reuse and recycle powders and parts,” said Ellen Jackowski, chief sustainability and social impact officer, HP. “Our collaboration with Ford extends the environmental benefits of 3D printing even further, showcasing how we are bringing entirely different industries together to make better use of spent manufacturing materials, enabling a new circular economy.”

For its part, Ford is developing new applications and utilising a multitude of different processes and materials for 3D printing, including filaments, sand, powders and liquid vat polymerisation. The company already employs 3D printing for a variety of low-volume commercial vehicle parts, as well as fixtures used by assembly line workers use, saving production time and enhancing quality.

 

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SLM Solutions Signs MoU For The Purchase Of Five NXG XII 600 With Major European OEM

 

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EOS And Audi Expand Range Of Applications For Metal 3D Printing

EOS And Audi Expand Range Of Applications For Metal 3D Printing

AUDI AG is relying entirely on industrial 3D printing at its Metal 3D Printing Centre in Ingolstadt for the production of selected tool segments. Additive manufacturing (AM) with EOS technology is used for 12 segments of four tools for hot forming. Plans call for significantly more segments to be printed this way. Audi uses the tool segments produced using the EOS M 400 system in its press shop to make body panels for models including the Audi A4. The company plans to do the same for future electric vehicles.

Shifting part of its tool segment production activities from conventional manufacturing to AM is an important step, highlighting both the quality and reliability of industrial 3D printing and the design freedom advantages this production method offers. This is the latest outcome of the longstanding cooperative relationship between Audi and EOS in Ingolstadt. EOS provided support in the form of technology and know-how before and during the construction of Audi’s 3D printing centre back in 2016. Since then, experts from both companies have been making steady progress on the use of AM, and Audi has established an ideal application in the area of hot forming for series vehicles. Several hundred thousand parts have already been produced using the 3D-printed tools and installed in selected models.

“From initial qualification by EOS to internal further development and refinement of the entire process chain through to standardisation of a new production method, we are now reaping the fruits of years of development within Audi’s production organisation. Whenever conventional manufacturing methods reach their limit, we use additive manufacturing – which lets us meet quality standards and comply with production times,” said Matthias Herker, Technical Project Manager at the Audi Metal 3D Printing Center

Advantages of 3D printing for tooling

When additive manufacturing is used at the Audi Metal 3D Printing Center, the focus is on hot forming segments and high-pressure die casting tool inserts. The design department in Ingolstadt creates entire tools, which can measure as much as 5 x 3 meters. The individual additively manufactured tool segments in turn can be up to 400 mm in length and weigh as much as 120 kg. The size and complexity of the tool segments mean that construction times of up to 20 days are not uncommon, which is why the reliability and quality of the EOS M 400 3D printing system that is used are crucial success factors.

3D printing makes it possible to create highly complex cooling channels configured for the specific component within the tool segments. This provides contoured, more-even cooling, making it possible to shorten cycle times with outstanding quality – a critical point for series production of the actual vehicle component.

 

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SLM Solutions Signs MoU For The Purchase Of Five NXG XII 600 With Major European OEM

 

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ExOne And Ford Develops Automotive Industry-First Binder Jet Aluminum 3D Printing And High-Density Sintering

ExOne And Ford Develops Automotive Industry-First Binder Jet Aluminum 3D Printing And High-Density Sintering

In a project co-funded by Ford Motor Company and the ExOne Company, a team of engineers, material scientists, and manufacturing experts has developed a patent-pending process for rapid and reliable binder jet 3D printing and sintering of aluminum that delivers properties comparable to die casting.

Delivering a commercially viable achievement in this area has evaded researchers for more than a decade. The new process is expected to increase Ford’s efficiency by allowing the company to affordably produce complex parts uniquely designed for additive manufacturing, which enables size and weight reductions, part consolidation, and performance improvements.

“This is a breakthrough in making 3D printed and sintered parts for the auto industry,” said Harold Sears, Ford technical leader for additive manufacturing.

“While the 3D-printing process is very different than stamping body panels, we understand the behavior of aluminum better today, as well as its value in light-weighting vehicles. High-speed aluminum 3D printing paves the way for other opportunities that we’re just now starting to take a look at because of the ability to do complex parts with aluminum that previously weren’t possible. It’s really opening doors for other opportunities.”

“Developing a fast, affordable, and easy way to 3D print aluminum with traditional material properties is a critical step toward light-weighting more products and delivering a more sustainable future,” said John Hartner, ExOne CEO.

The new innovation came about through the process of binder jetting, widely regarded as the fastest method of metal 3D printing for high-volume output. It uses a digital file to quickly inkjet a binder into a bed of powder particles such as metal, sand, or ceramic to create a solid part, one thin layer at a time. When printing metals, the final bound metal part must be sintered in a furnace to fuse the particles together into a solid object. The heating process reinforces the strength and integrity of the metal, and while the process for sintering stainless steel is well understood, achieving high densities greater than 99 percent is an industry breakthrough for aluminum.

 

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How 3D Printed Injection Moulds Can Reduce Production Time & Tooling Cost

How 3D Printed Injection Moulds Can Reduce Production Time & Tooling Cost

As we all know injection moulding requires high initial investment, specialist equipment and lead time for tooling, this can significantly hinder the speed and cost to introduce new products to the market. However, with the continuous advancements in additive manufacturing 3D printing technology is now offering a cost-cutting, agile alternative solution to quickly design and fabricate mould for small runs of thermoplastics prototypes or end-use parts.

What is injection moulding?

Injection moulding is one of the leading processes for manufacturing plastics as it yields high-quality parts and is cost effective. Widely used for mass-producing identical parts with tight tolerances, it is a fast, intensive process where high heat and pressure are involved to melt thermoplastic and force it inside a mould.

Because of these extreme moulding conditions, the tools are traditionally made out of metal by CNC machining or electric discharge machining (EDM). However, these are expensive industrial methods that require specialised equipment, high-end software, and skilled labour.

Manufacturers are now turning to 3D printing to fabricate injection mould rapidly and at low cost. They can benefit from the speed and flexibility of in-house 3D printing to create the mould and couple it with the production force of injection moulding to deliver a series of units from common thermoplastics in a matter of days.

Challenges

Even though 3D printing moulds can offer these advantages when used appropriately, there are still some limitations. We should not expect the same performance from a 3D printing polymer mould as from a machined metallic one. Critical dimensions are harder to meet, cooling time is longer because the thermal transfer occurs slower in plastic, and printed moulds can easily break under heat and pressure. However, low-run injection moulds are great assets for engineers to deliver limited batches of end-use parts or prototypes in the final plastic, for pre-production tests.

Unlocking in demand mould fabrication with stereolithography (SLA)

Stereolithography (SLA) printing technology is a great choice for moulding. It is characterised by a smooth surface finish and high precision that the mould will transfer to the final part and that also facilitates demoulding.

In a recent webinar, Formlabs discusses how SLA printing enables in-demand mould fabrication to generate hundreds of parts, from idea to production, in a matter of days, at a fraction of the cost. Catch the re-run of the webinar here, and learn:

  • Expert processes to design a 3D printed mould for injection moulding.
  • Which printing and moulding conditions ensure success, including an overview of the Formlabs resins that Novus Applications and Braskem use for the moulds.

Strategies for the post-processing workflow, including ejection and demoulding

Real-life applications

Access the full white paper here and have a closer look at how this hybrid manufacturing process enables on-demand mould fabrication to quickly produce small batches of thermoplastic parts through real-life case studies with Braskem, Holimaker, and Novus Applications.

For more information, click here for an overview of methods and guidelines for using SLA 3D printed moulds in the injection moulding process.

 

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AMEXCI And SLM Solutions Strengthen Partnership To Accelerate Industrialisation Of Metal AM

AMEXCI And SLM Solutions Strengthen Partnership To Accelerate Industrialisation Of Metal AM

AMEXCI, an Additive Manufacturing company, founded by eleven Nordic based industrial companies and Selective Laser Melting pioneer SLM Solutions have strengthen their partnership. The joint objective is to further accelerate the industrialisation of metal-based Additive Manufacturing and support companies to successfully implement AM technologies for serial production of complex metal parts. To achieve this and to create the basis for increased productivity and part quality, AMEXCI has invested in the Selective Laser Melting machine SLM 500, equipped with four 700 W lasers.

Edvin Resebo, CEO of AMEXCI underlines: “Having worked together for some time we are happy to take the next steps and further strengthen the cooperation between AMEXCI and SLM Solutions as we see their technology as a strong complement alongside our existing collaborations. Regarding the industrialisation of AM, we see a growing potential in the Nordic region for the coming years. From an AMEXCI perspective, SLM Solutions showcases a strong understanding of what´s important and what needs to be in place for AM as an industrial manufacturing process.”

As part of the partnership, specific case studies will be used to evaluate Additive Manufacturing and test the competitive industry advantages of different machines and technologies offered by SLM Solutions. Additionally, AMEXCI evaluates the use of the recently introduced SLM machine NXG XII 600 for industrialised series production.

Sam O’Leary, CEO of SLM Solutions says: “AMEXCI works with a wide range of industries, especially in the Nordic region. We are proud to contribute as a solution partner to support and to realise AM business cases of their customers, from prototype up to serial production. Providing consulting services throughout the customer’s AM journey, is a goal of SLM Solutions in this partnership.”

The basis for the joint cooperation is AMEXCI’s investment in the latest SLM 500 from SLM Solutions. The machine offers excellent features for industrial series production. As the first quad-laser system on the market, the machine is ideally suited for the rapid cost-effective production of large metal parts. The multi-laser overlap strategy with up to four 700 Watt lasers ensures maximum efficiency. The ability to change the build cylinder minimises machine downtime, maximises productivity and reduces cost per part.

AMEXCI, together with its customers develops a new generation of products where AM acts as an enabler for higher competitiveness and more sustainable production. Furthermore, AMEXCI offers a wide range of trainings and workshops to build up successful business cases for their customers. At its AS9100D certified lab in Karlskoga, Sweden, AMEXCI has the capability to design, produce and qualify components. Founding shareholders of AMEXCI are ABB, Atlas Copco, Electrolux, FAM, Husqvarna Group, Höganäs AB, Saab, Scania, SKF, Stora Enso and Wärtsilä.

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3D Systems’ Metal AM Solutions Selected By Raytheon Technologies And CCDC Army Research Laboratory For Novel Thermal Application

3D Systems’ Metal AM Solutions Selected By Raytheon Technologies And CCDC Army Research Laboratory For Novel Thermal Application

3D Systems has been selected by Raytheon Technologies and the Combat Capabilities Development Command (DEVCOM) Army Research Laboratory (ARL) as part of a research project titled “Research for Virtual Design and Qualification Process for Additively Manufactured Parts Optimised for Multi-Laser Machines” awarded through the National Center for Manufacturing Sciences’ (NCMS) Advanced Manufacturing, Materials, and Processes (AMMP) program.

Working in conjunction with Raytheon Technologies, the Penn State Applied Research Lab, Johns Hopkins University, and Identify3D, the goal is to optimise a component relative to an Army modernisation product to maximise cooling and improve overall system performance. Using additive manufacturing (AM) to address this need is a novel approach to the project that covers the entire part lifecycle including determining performance requirements, topologically optimising the design, manufacturing the part with attention to process monitoring for quality control, component performance validation, and data security.

Dr. Brandon McWilliams, deputy program manager at the CCDC ARL Weapons and Materials Directorate states, “The novel integration and concurrent design of structures, materials, and processes to create topologically optimised heat exchangers will enable disruptive advancements in munitions technology in support of multiple Army Modernisation Priorities.”

The size and complexity of this specific application require a large frame AM system. 3D Systems’ Application Innovation Group (AIG) designed a bespoke solution built on the company’s DMP Factory 500 solution for its best in class build volume (up to 500 x 500 x 500 mm) and its ability to produce parts spanning the entire build area without the need for stitching. The AIG has architected a custom configuration of the DMP Factory 500 that includes multiple modules to meet the unique requirements of this application. This advanced metal production system recently installed and commissioned at Penn State’s Center for Innovative Material Processing through Direct Digital Deposition (CIMP-3D) in December 2020, will be powered by the company’s 3DXpert additive manufacturing software and LaserForm materials. This particular printer will be upgraded with some of the innovative technologies 3D Systems is working on for its 9-laser, 1m x 1m x 600mm metal 3D printer including coaxial process monitoring and a high contrast single-lens reflex (SLR) camera within the build chamber that delivers a comprehensive view of the build insitu. By using the same optical train included in the even larger frame, 9-laser system, the development activity on the DMP Factory 500 will be directly transferrable to the larger system. 3D Systems’ AIG application experts will continue to provide support throughout the project, including design guidance and training.

“Our work with the Army Research Laboratory is taking 3D Systems’ technology in new directions,” said Chuck Hull, co-founder and chief technology officer, 3D Systems. “We’re able to combine our metal 3D printing innovation with unique advancements in process modeling and monitoring, data security, and topology optimisation to deliver an unparalleled solution. ARL is strengthening its position as a leader in technology innovation to improve the capabilities of the warfighter and we look forward to continuing our collaboration with them.”

In addition to the thermal application, this team will also develop and evaluate new technology for process modeling and defect prediction, process monitoring and defect detection, topology optimisation, and cyber-physical security.

“The migration to larger build envelopes significantly expands the domain of Department of Defense applications addressable by additive manufacturing, yet it brings new challenges for process monitoring and quality control,” said Ted Reutzel, associate research professor, Penn State’s Applied Research Lab, and director, Penn State’s CIMP-3D. “The installation of this system at our Center will enable our team to leverage prior developments—funded by the US 3D Systems Press Release Page 3 Navy, US Air Force, America Makes, and others—to help meet these challenges and rapidly integrate advanced flaw detection technologies.”

“The team is establishing a singular fluid architecture that encompasses design optimisation, sensing, machine learning, security, testing, and production,” said Lisa Strama, president and CEO of NCMS, a cross-industry technology development consortium. “This will result in a prototype-based upon a holistic, machine agnostic, interconnected workflow. Leveraging the NCMS’ AMMP program and our trusted collaborative model, this project fully showcases the advancements made possible and efficiencies gained when bringing together OEMs, nontraditional defense contractors, and academia to address the full life-cycle of Army relevant components.”

“Identify3D is proud to be part of this program by providing end-to-end protection of the core manufacturing process from build file generation to DMP Factory 500 production and sensor data generation,” said Chris Adkins, chief scientist, Identify3D. “In addition to the DMP Factory 500 integration, Identify3D is developing an architecture to securely collect sensor data in the inspection and defection detection workflow as well as secure the design and defect prediction process to ultimately optimise the full digital workflow.”

 

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Three Ways Additive Manufacturing Defined 2020

Three Ways Additive Manufacturing Defined 2020

While additive manufacturing has been trending toward mass adoption for some time, the global pandemic has accelerated this momentum. Here are three ways how metal 3D printing has defined manufacturing this year. Article by Richard Elving, Markforged.

While 3D printing has been around since the 1980s, advancements in technology and the unprecedented supply chain disruption due to COVID-19 have driven more mainstream adoption throughout 2020.  While the pandemic has wreaked havoc on global business, causing shutdowns and spikes in demand, we’ve also heard positive stories of true innovation from businesses across the manufacturing sector.

Markforged’s inaugural annual COVID-19 Impact on Supply Chains: Global Additive Manufacturing Industry Report found that modern manufacturers—or, those who adopt digital manufacturing solutions such as 3D printing—were the most resilient during the pandemic, reporting that they’ve been operating “business as usual,” while other manufacturers scaled production back. 

Based on research conducted with our global customer base and the wider industry, the report notes that almost one quarter (24 percent) of our customer respondents said they had begun producing new products during the pandemic, and 45 percent stated that “nothing has changed, it’s business as usual.” With 28 percent of customer respondents noting that they are now using 3D printing more compared to pre-pandemic usage, it’s clear that 2020 has been a year that we will look back upon as an inflection point for additive technologies. 

While additive manufacturing has been trending toward mass adoption for some time, the global pandemic has accelerated this momentum. Here are three ways we’ve seen metal 3D printing define manufacturing this year.

  1. Identifying Solutions to Supply Chain Delays

In March and April of 2020, we saw supply chains across the globe break. Whether it was from unpredictable supply and demand patterns, unreliable suppliers or broken line parts that could not be traditionally replaced, the manufacturing industry was devastated. As international supply chains continue to strain while we continually battle the virus, manufacturers want more control over their supply chains. 

But, by turning to the flexible solutions offered by 3D printing, manufacturers were able to rapidly engineer robust solutions and simplify their logistics. By leveraging printers to solve their supply chain problems, manufacturers were able to remain resilient in the face of unprecedented difficulties.

One of Markforged’s customers, an orthopaedics business, was one organisation that was able to streamline its manufacturing processes with the help of an industrial 3D printer. Extended waiting times for a specific medical grade raw material casting forced this business to explore all of the options available to them–including the printer they were already using to print tooling jigs and fixtures. They printed a duplicate of the raw cast part they were waiting for and were able to perform full test runs of their manufacturing process. 

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SLM Solutions Signs MoU For The Purchase Of Five NXG XII 600 With Major European OEM

SLM Solutions Signs MoU For The Purchase Of Five NXG XII 600 With Major European OEM

A major European OEM has signed an (Memorandum of Understanding) MoU to purchase five NXG XII 600 machines, with the first machine delivery in 2022. The agreement also facilitates the reservation and allocation of production-slots.

In November 2020, SLM Solutions unveiled the NXG XII 600 boasting 12 lasers, each with 1 kW power and a build envelope of 600x600x600mm. Its arrival marks a breakthrough in the additive manufacturing (AM) sector and paves the way for industrial serial production. Combined with innovative technical features, maximum productivity and reliability, it proves SLM Solutions’ technological leadership in the AM manufacturing industry. The customer will be one of the first global companies to take advantage of its benefits and intends to implement it for serial production.

Sam O’Leary, CEO of SLM Solutions explains: “When we launched the NXG XII 600, we knew it would disrupt the industry and spark a new era for manufacturing. Therefore, this MoU just two months after the launch is an exciting milestone for the company.  It validates our vision that the OEMs can implement innovative additive manufacturing technology for serial production into their business models.” He then went on to say that: “The NXG XII 600 accelerates the future of metal additive manufacturing, and our engineers have further pushed the boundaries of what is possible.”

Additive Manufacturing can lead to numerous commercial and technical advantages allowing companies to strengthen their competitive positions. It requires knowledge in additive manufacturing, but above all, robust and productive machines. The SLM Solutions’ NXG XII 600 takes manufacturing to a new level and enables the production of complex, high-quality metal parts in only a few hours.

O’Leary further states: “This MoU underlines that not only are we prepared to step forward to the industrialisation of metal additive manufacturing, but the marketplace is ready as well.”

The final binding agreement will be signed by Q2 2021.

Additionally, a further beta machine contract has been concluded with another customer. This machine will be delivered in Q2 2021.

Click here to learn more about the NXG XII 600 and its applications from SLM’s customers! 

 

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CERATIZIT Wins Innovation Award For The Additive Manufacturing Of Carbide Parts

CERATIZIT Wins Innovation Award For The Additive Manufacturing Of Carbide Parts

The CERATIZIT Group has won the 2020 Innovation Award of the FEDIL business federation in the ‘Process’ category for the development of a new process for the additive manufacturing of tungsten carbide-cobalt. Thus, the Luxembourg hard materials specialist has established itself as a pioneer in the additive manufacturing of cemented carbide components.

The additive manufacturing of components made of plastic, steel and other materials has continued to grow in importance over the last few years. However, in the case of cemented carbide, there had not been a reliable process so far that achieved the same standard of quality as the manufacturing processes that had been established and optimised over decades. With its newly developed process, CERATIZIT not only achieves the customary quality of products manufactured by pressing and machining but can also respond better to customer requirements, as Head of R&D Dr. Ralph Useldinger explained:

“Additive manufacturing of carbide products provides us with more flexibility in terms of implementing customer requirements and opens new design possibilities, which we can use to offer our customers highly optimised, individual solutions in minimum time.” This also includes active support in optimising product design, as Useldinger emphasised.

Faster delivery at lower costs

One of the main advantages of the additive manufacturing of cemented carbide is the time and cost savings during the critical ramp-up of products in small batches and of high complexity such as the manufacturing of prototypes. By producing the geometry directly from the design software, 3D printing allows for the fast planning and implementation of projects, without the use of production-intensive shapes and dies as well as expensive, diamond-tipped tools which are needed for the machining of carbide parts. This undoubtedly saves a lot of valuable time and money, particularly in the development of prototypes.

More freedom of design

The second big benefit of additive manufacturing is the wider range of possible shapes due to the direct production of free-form contours which go way beyond the limits of traditional manufacturing processes. Thanks to the new process, geometries can now be manufactured that were previously considered unfeasible. These include, for instance, structures that have undercuts or areas inaccessible to cutting tools such as cavities and channels inside the finished body which cannot be accessed from outside at a later stage. This innovation enables a higher degree of component complexity as well as a deeper level of integration while at the same time reducing the number of assemblies and individual components.

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