Multi-Material Design using 3D Printing

Project Information

MADE-3D

Grant agreement ID: 101091911

DOI

10.3030/101091911

Project closed

EC signature date 18 November 2022

Start date 1 January 2023

End date 30 June 2026

Funded under

• Digital, Industry and Space

Total cost

€ 5 483 257,50

EU contribution

€ 5 482 007,25

Coordinated by

UNIVERSITAET PADERBORN
Germany

Periodic Reporting for period 2 - MADE-3D (Multi-Material Design using 3D Printing)

Reporting period: 2024-07-01 to 2025-06-30

Summary of the context and overall objectives of the project

MADE-3D aims to transform additive manufacturing (AM) by tackling the challenges of producing complex, multi-material components. Conventional methods often face difficulties in optimizing lightweight structures and combining different materials due to residual stresses, cracks, and thermal mismatches. MADE-3D addresses these issues by developing efficient, sustainable, and flexible production processes that meet the growing demand for complex components with specific properties in industries like automotive, aerospace, and aeronautics.
The project focuses on developing new multi-material combinations, such as Aluminum-Copper, Nickel-Titanium, and various steel alloys, specifically optimized for Powder Bed Fusion-Laser Beam (PBF-LB) and Directed Energy Deposition (DED) processes. Advanced design and simulation tools are also employed to optimize multi-material structures, with a particular emphasis on topology optimization to meet performance requirements while reducing material use.
A strong focus on sustainability has driven the development of innovative recycling strategies for both bulk and powder materials, including methods for reusing powder waste and end-of-life components, significantly improving the environmental impact of AM technologies. To ensure further innovation, MADE-3D integrates computational material engineering by combining thermodynamics, microstructure predictions, and process simulations with machine learning. This approach accelerates development cycles, improves predictability, and enhances control over AM processes.
By overcoming the challenges of multi-material AM, MADE-3D facilitates the production of lighter, stronger, and more efficient components, aligning with EU manufacturing goals. Economically, the project spurs innovation and opens new market opportunities, especially for SMEs, by reducing material waste and increasing efficiency. Environmentally, MADE-3D supports the EU’s Green Deal and circular economy objectives by emphasizing recycling and sustainability, thereby promoting resource efficiency. Technologically, the project sets new standards in digital manufacturing, positioning the EU as a global leader in AM.
MADE-3D’s scalable technologies aim to reduce material waste, component weight, and environmental impact, making multi-material AM a valuable enhancement to traditional manufacturing techniques.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

One of MADE-3D’s key achievements is the design of materials that tackle challenges like residual stresses, cracks, and thermal mismatches, which often hinder multi-material applications. Through extensive testing and iterative improvements, the project identified alloys with enhanced mechanical properties suitable for Powder Bed Fusion-Laser Beam (PBF-LB) and Directed Energy Deposition (DED) processes. Process optimization focused on refining parameters such as laser power, scanning speed, and layer thickness, resulting in improved stability and higher-quality components.
Advanced design and simulation tools were developed to optimize multi-material structures, addressing specific performance requirements through simulations of load cases, thermal stresses, and topology optimization. These simulations were crucial in validating material combinations, ensuring that components met industrial standards while minimizing material use.
To further improve material development, MADE-3D integrated computational material engineering, combining thermodynamic models, microstructure predictions, and process simulations with machine learning. This integration allowed for accurate predictions of material behavior during AM processes, significantly shortening development cycles and reducing experimental needs. Machine learning algorithms analyzed large datasets, enhancing the prediction of optimal processing conditions and material properties.
Additionally, MADE-3D explored recycling strategies for multi-material AM, including methods for reusing powder waste, post-processed waste, and end-of-life components. Techniques like material reprocessing and purification were tested, demonstrating that AM materials can be reused without significant loss of quality or performance, thus enhancing sustainability.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

MADE-3D has advanced multi-material additive manufacturing (AM) by overcoming material combination challenges, optimizing processes, and developing innovative recycling strategies. These advancements improve AM's performance, reliability, and sustainability, making it more appealing to industries like automotive, aerospace, and aeronautics. The project boosts European competitiveness with lighter, stronger, and more efficient components, reduces material waste, lowers production costs, and decreases manufacturing’s environmental impact, aligning with EU sustainability and resilience goals.
To ensure developement, ongoing research and demonstrations are crucial for refining alloys and processes, addressing technical challenges, and validating technology in real-world settings. Access to markets and finance through targeted support, funding, and investor engagement is essential for scaling up technologies.
Effective commercialization strategies, including intellectual property protection, licensing, and business development, will facilitate market entry. Expanding into global markets through internationalization will enhance MADE-3D’s impact. Collaborating with international partners and participating in global AM networks can promote broader adoption. Additionally, establishing supportive regulatory and standardization frameworks, including new standards for materials, processes, and recycling, will ensure consistency and quality, supporting the widespread adoption of multi-material AM.

Project Logo

Illustration of Approach