Manufacturing and Materials Technology (FWT)

Motivation and aim

The development of new products is a central engineering task that can only be mastered on an interdisciplinary basis, i.e. in cooperation between product development, production and materials engineering. This is due to the fact that the component properties required in development are significantly influenced by the individual process steps from raw material or semi-finished product to the finished component. In view of the high level of development of available processes, the associated issues are considered a priority topic for research work in manufacturing technology. The primary objective of the Manufacturing and Materials Engineering research area is process (chain) optimization and control to improve component quality and resource efficiency in additive and machining processes using software-based methods. The research area is divided into the two groups Cutting (Prof. Schulze) and Additive Manufacturing (Prof. Zanger). The common strategic topics are surface engineering, sustainability and digitalization.

Contact:
Prof. Dr.-Ing. habil. Volker Schulze

Prof. Dr.-Ing. Frederik Zanger

Topics

Precision Machining

Gear Engineering

Additive Manufacturing

Turning
Drilling
Milling
Stream Finishing
Combined processes for process chain consolidation
Simulation of manufacturing processes (chip formation, cooling strategies, particle flow)
Software-based process design and control
Targeted setting of surface layer states

Soft- and hard machining for skiving
Whirling and special processes for thread production and polygonal manufacturing
Special kinematics for precision gearing
Simulative tool design
Analysis of local parameters and mechanisms
Topography and component quality prognosis and optimization

Powder Bed Fusion (PBF)
Vat Photopolymerization (VPP)
Hybrid components through material and process hybridization
Development of metal powders and slurries (ceramics, magnets)
Digitization of additive manufacturing process chains
Process simulation on different scales
In-situ-microstructure adjustment
Post-processing to set component properties

Contact:

Contact: M.Sc. Andreas Hilligardt

Contact:

Selected Focus Topics

Simulation of chip formation	Broaching	Skiving	Mikro-EDM
Acoustic process control	Ultra-precision machining	Surface structuring	Machining of fiber-reinforced composites
Process Chains in Production	Process-Machine-Interaction	Surface engineering

Research Projects

CZS Center KRAFt CZS Center for Circular Economy and Resource Efficiency via Additive Manufacturing Technologies	Simon Linnemann, M.Sc. Marvin Rothmeier, M.Sc. Marvin Dornick, Dipl.-Ing. Prof. Dr.-Ing. Frederick Zanger	01.04.2025 - 31.03.2031
AddDEM Characterization of technical powders for multiscale modeling of particle processes using the example of metallic additive manufacturing	Kai Drechsel, M.Sc.	01.05.2023 - 31.10.2024
AddBroach Sustainable production of near-net-shape semi-finished products by means of binder jetting using the example of broaching tools	Daniel Mayer, M.Sc. Johannes Schubert, M.Sc.	01.05.2023 - 31.10.2024
MultiPower Spatially optimised manufacture of a power module using stereolithographic multi-material fabrication of ceramic 3D substrates with embedded conductive structures	Chantal-Liv Lehmann, M.Sc. Prof. Dr.-Ing. Frederik Zanger	01.04.2023 - 31.07.2025
AddXChange Holistic qualification of copper for the binder jetting process with targeted porosity adjustment on the basis of heat exchangers for electromobility	Daniel Mayer, M.Sc. Johannes Schubert, M.Sc.	01.01.2023 - 31.12.2024
AddFlow Flow-adapted components for fuel cells through additive-subtractive manufacturing with adjustable surface function (hydrophobic, hydrophilic)	Maximilian Frey, M.Sc.	01.01.2023 - 31.12.2024
AddBite Development of patient-specific additively manufactured mandibular implants with biotechnology-inspired functional lattice structures	Nico Ulff, M.Sc. Prof. Dr.-Ing. Frederik Zanger	15.08.2022 - 31.07.2025
AddAlB4C Aluminum-B4C composites for powder bed-based selective laser melting.	Victor Lubkowitz, M.Sc.	01.07.2022 - 30.06.2024
KADDISH Cooling channels in the additively manufactured grooving tool	Patrick Fischmann, M.Sc.	01.02.2022 - 31.07.2023
AddPEM - Additive manufacturing of graded flow structures for po Additive manufacturing of graded flow structures for polymer electrolyte membrane (PEM) fuel cells.	Victor Lubkowitz, M.Eng. Maximilian Frey, M.Sc.	01.01.2022 - 31.12.2023
AddTemp Additive manufacturing of specific microstructures through local and global temperature control	Kai Drechsel, M.Sc.	01.01.2021 - 31.12.2024
ICM Junior Research Group Advanced Manufacturing A versatile and universally applicable manufacturing technology for the development of mobility solutions for tomorrow and for production technology itself.	Steffen Kramer, M.Sc. Prof. Dr.-Ing. Frederik Zanger	01.10.2020 - 30.09.2025
DFG GRK 2078: International Research Training Group CoDiCoFRP Integrierte Entwicklung kontinuierlich-diskontinuierlich langfaserverstärkter Polymerstrukturen	Jannis Langer, M. Sc.	01.04.2015 - 31.03.2024