3D printing research bridging the gap

35 candidates applied for one of the eight presentation slots in the Science Forum on 13 May 2025 at rapid.tech 3D. Other applicants will nevertheless be able to showcase their work at Germany’s longest-running trade AM event.

Even more visibility for the AM science community 

“We want to make the rapid.tech 3D science community even more visible. That’s why last year we organised a poster slam alongside the trade forum, where we displayed selected contributions. We’re doing the same again this year. This gives a further 15 candidates who took part in this year’s call for papers the opportunity to present their research findings in an informal atmosphere, to exchange ideas with visitors, speakers and exhibitors, and to network,” says Dr Stefan Kleszczynski, acting head of the Manufacturing Technology Department of the University of Duisburg-Essen’s Institute of Product Engineering and member of the rapid.tech 3D advisory board. He adds that the publication partnerships launched in 2024 with the Springer Nature journal “Progress in Additive Manufacturing” and the RTe Journal will also be continued, bringing rapid.tech 3D to an even wider international audience. “This motivates young scientists in particular to present their research in Erfurt,” Dr Kleszczynski points out.  

Degree of innovation as a selection criterion

Submissions for the publications and the presentation slots undergo a rigorous scientific review process, with leading experts in German AM research evaluating the papers received. Entries demonstrating the highest degree of innovation were awarded one of the coveted eight presentation slots in the trade forum. “Our aim is to address the latest work in basic research as well as to showcase projects that are of particular industrial relevance. This means we can look at 3D printing research in a way that bridges the gap between what’s already possible today and the potential for tomorrow,” says Dr Kleszczynski. 

New pathways in antenna manufacturing 

Research being conducted at the University of the Bundeswehr Munich on the additive manufacturing of high-frequency quadrupoles, a key component in linear particle accelerators, is of practical relevance. Research assistant Stefan Brenner reports on how, for the first time, a prototype has been produced using multi-material laser powder bed fusion. It is not conventionally possible to integrate different materials in a single production step, so this opens up new avenues in antenna manufacturing. 

Data-based approach to tackle “certification bottleneck”

In many areas, certification processes create a “bottleneck” in production, hampering efficiency and scalability. Wolfram Groh, research assistant at TU Dresden, presents a data-based certification approach for additively manufactured aircraft components that uses machine learning algorithms and achieves results faster than existing methods. This approach can be rolled out to other areas. 

Additive manufacturing of wear-resistant tool components

Leon Engelhardt, research assistant at the Rheinische Hochschule Köln, demonstrates the potential of laser-based powder bed fusion of tungsten carbide-nickel composites for the additive manufacturing of wear-resistant tool components. When combined with sinter-HIP (pressure-assisted sintering), it is possible to manufacture dense, wear-resistant components that are very tough and can accommodate complex designs.

New measuring method for monitoring temperature during metal laser melting

Hanna Schönrath, research assistant at the University of Duisburg-Essen, presents a novel approach to determining temperatures in-situ during the laser-based powder bed fusion of metals. The new method, which uses phosphor thermometry, means that temperature cycles in additive manufacturing processes can be better monitored.

New polymers for additive manufacturing

Presentations by Simon Cholewa, research assistant at the University of Erlangen-Nuremberg, and Paul Roumeliotis, a doctoral student at the same institution, will focus on new materials for additive manufacturing. Simon Cholewa examines the advantages and disadvantages of polybutylene terephthalate as a new material for the laser powder bed fusion of polymers. It enables the production of rigid, functional components, but is also susceptible to brittle fracture and there are limits on how it can be processed.

Paul Roumeliotis presents a new flame retardant system for polyamide 12 in selective laser sintering. LOI testing, which is used to assess the flammability of plastics, confirms the effectiveness of the flame retardant system, with increasing additive content enhancing flame retardancy.

Focus on sinter-based additive manufacturing and material extrusion printing

David Stachg, research assistant at Hamburg University of Applied Sciences, and Verena Witt, process engineer at New AIM 3D GmbH Rostock, a spin-off company of the University of Rostock, will be discussing the potential of sinter-based additive manufacturing processes and material extrusion printing.

David Stachg investigates the properties of components manufactured using the sinter-based processes cold metal fusion (CMF) and metal fused filament fabrication (MFFF). The findings demonstrate the development of a component design that enables a “first time right” approach, thus unlocking the economic potential of these processes and ensuring their sustainability.

Verena Witt presents a novel approach to mitigate anisotropic, i.e. direction-dependent, material behaviour in material extrusion printing. This helps to enhance the mechanical properties of additively manufactured plastic components.

Specialist conference offers a look at other current AM developments and applications

Alongside the Science trade forum, other forums at the rapid.tech 3D specialist conference will provide insights into the latest developments and applications in additive manufacturing. On the first day, in addition to the Science Forum, the VDMA AM4industry Forum and the Aerospace Forum invite visitors to delve into these topics. Day two of the programme includes the Chemistry & Process Engineering, Electronics & Components, and Mobility forums. The final day of the conference will focus on Software, AI & Design, Energy Technology & Hydrogen, and Innovations in AM.

Presentations and a chance to chat to exhibitors, Deep Dive tours and Expert Tables 

Visitors can also look forward to product and service demonstrations as well as small group discussions in Hall 2 – at the exhibitors’ stands or on guided Technical Deep Dive tours, at the Expert Tables, and at the AM Science Poster Slam in the hall.

The 3D Pioneers Challenge too is a source of inspiration, introducing completely new applications of additive and digital technologies. This year the international competition is back at rapid.tech 3D for the tenth time. The anniversary edition gives all previous finalists and winners the chance to go before the jury panel once again and scoop the title of “Pioneer of the Decade”.