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Multi-Material Design using 3D Printing

Project description

Revolutionary AM process for multi-material components production

Multi-material components offer unparalleled benefits to the production and use of lightweight structures, allowing for their optimisation according to their specific roles. Additive manufacturing (AM) creates opportunities to improve the production process of multi-material components and make the process cheaper and less complicated. Unfortunately, the production process of these components has not yet been successfully transferred to AM and is still inefficient. The EU-funded MADE-3D project aims to change this by using PBF-LB and DED printing processes to design and develop novel efficient processes for AM production of multi-material compounds.


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 multi-material 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 end-users cover automotive, aerospace and aeronautic applications with specific use cases.



Net EU contribution
€ 887 825,00
Warburger strasse 100
33098 Paderborn

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Nordrhein-Westfalen Detmold Paderborn
Activity type
Higher or Secondary Education Establishments
Other funding
€ 0,00

Participants (10)

Partners (2)