Process Chains

The performance of Additive Manufacturing is not determined by the build process alone. Component quality, economic efficiency and industrial scalability depend on the interaction of the entire process chain from powder production and manufacturing to post-processing, inspection, data management and final application. Within the Process Chains research area, we therefore take a holistic view of Additive Manufacturing and analyze the interactions between individual process steps.

A central focus of our research is the question of how process chains can be described, simplified and systematically optimized. We investigate both upstream and downstream manufacturing steps and assess their influence on process stability, material condition and the resulting component properties. Our goal is to translate local improvements of individual process steps into robust and reliable overall solutions.

Particular attention is given to reducing and deliberately shaping preprocessing and post-processing steps. Already during component design and process planning, we analyze how build orientation, support structures, exposure strategies and thermal boundary conditions can be adapted to minimize subsequent processing requirements or prepare components more effectively for downstream operations. This helps reduce lead times and material consumption while increasing the robustness of the overall process chain.

In addition, we investigate hybrid manufacturing approaches in which additive and conventional processes are deliberately combined. The integration of milling, heat treatment, surface finishing and inspection technologies enables the production of highly precise and functionalized components within coordinated process chains.

Another focus lies on powder cycles and material-related interactions within additive manufacturing environments. We investigate the production, characterization, aging and reuse of metallic powders, as well as their influence on process behavior, defect formation and component quality.

Our research combines manufacturing technology, materials science, process simulation and production systems in a holistic approach to modern industrial manufacturing. Our goal is to develop robust, economically viable and resource-efficient process chains that advance Additive Manufacturing from isolated individual processes toward integrated and scalable production systems.