Within the Process Fundamentals research area, we investigate the physical and materials-science principles underlying additive manufacturing processes. This includes, among other aspects, energy input, thermal interactions, solidification behavior, as well as the resulting microstructure and component properties. This fundamental understanding is essential for defining robust process windows, ensuring reproducible quality and systematically transferring processes to new materials, geometries and operating conditions.

Smart Monitoring focuses on data-driven process observation and quality assurance. We develop concepts for the intelligent use of sensor and process data ranging from in-situ and inline monitoring approaches to signal interpretation and models for evaluating process states and detecting anomalies at an early stage. Our goal is to increase process transparency, reduce scrap and provide a robust basis for automation, traceability and quality verification.

Additive Manufacturing becomes particularly powerful when processes are controlled adaptively rather than through fixed parameter sets. In Adaptive Processing, we investigate strategies for dynamically adjusting process parameters to current process states and component requirements. For example, to compensate for thermal effects, complex geometries or variations between material batches. The result is greater process robustness, improved component quality and an important step toward closed-loop process control.

Additive Manufacturing is part of a broader value chain. And this is where its practical viability is ultimately determined. Within the Process Chains research area, we consider the entire process chain: material and preparation, manufacturing, heat treatment, post-processing, inspection, as well as documentation and data flows. We optimize interfaces and combine additive and conventional manufacturing processes to holistically improve quality, cost efficiency, lead times and scalability.

Within the Application & Transfer research area, we translate scientific findings into practical applications: Through demonstrator-based development, close collaboration with industry and a clear focus on real-world requirements. Together with our partners, we develop use cases, qualifiable components, robust workflows and effective transfer formats ranging from pilot projects to long-term collaborations. At the core is one question: How can research be transformed into a solution that works reliably in everyday practice?