Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Illustration of the laser sintering process: After exposing the test components for tensile strength and dimensional accuracy, the coating unit moves in to apply a new layer of powder.
From 3D printing to series production: Digital process chain for plastic components in the automotive industry
In short
The project is developing a continuous AI-supported process chain for the additive manufacturing of plastic parts. Research and industry are working together to make 3D printing with new materials and digital methods suitable for series production.
In detail
The DigiAutoFab project aims to implement a continuous, digital, scalable, and series-production-ready process chain for the additive manufacturing of plastic components. The focus is on powder bed-based laser sintering (PBF-LB/P), which has so far only been used to a limited extent for the production of functionally usable components in the automotive industry.
As part of the project, all participating project partners are working together to fully exploit the potential of 3D printing for series production. The following core aspects are being integrated to realize the project:
- Establishment of an end-to-end workflow: from component development to finished production
- Integration of intelligent sensor technology for process monitoring in the 3D printer
- Use of a new, energy-efficient, and high-precision fiber laser
- Processing of glass bead-reinforced polypropylene and polyamide materials for the high demands placed on automotive components
- AI-supported analysis of process data for real-time quality assessment and dynamic process control
- Use of digital twins to link product and process data and for simulation-based optimization
The project partners and their contributions
- Fraunhofer IPA and IAO: Development of the digital end-to-end workflow, integration of sensor technology into the 3D printing process, AI-based process monitoring, creation of the digital twin, interfaces for post-processing and quality assurance.
- University of Stuttgart (IFSW & IFF): Research on laser and plant technology (IFSW), design and analysis of the manufacturing system, process data modeling, system integration, and evaluation (IFF).
- Leotech Rapid Prototyping und Werkzeugbau GmbH: Application and practical testing of the developed process chain, industrial requirements for component quality and cost-effectiveness, feeding back experience into process development.
- Porsche AG: Contribution of real requirements from vehicle development, validation of additively manufactured plastics for pre-series use, and evaluation of future potential for digitizing the process chain, shortening manufacturing times, and reducing manufacturing costs using the example of media-carrying components.
- WENZEL Group GmbH & Co. KG: Measurement technology solutions for quality assurance of additively manufactured components, particularly with regard to geometric precision, surface quality, and automated testing processes.
- DyeMansion GmbH: Post-processing and surface finishing of 3D-printed plastic parts, integration into the digital process chain, contribution to series production capability through standardized finishing processes.
- Nexedi GmbH: Development of IT infrastructure, platform integration, process data management, open software solutions for digital process networking (e.g., ERP-related solutions or open source frameworks).
- 4D Photonics GmbH: Integration of optical sensor technology for process monitoring, acquisition and evaluation of additional data sources (powder distribution, scanning strategy, installation space analysis) for error prevention.
Fraunhofer IPA is responsible for the development and optimization of process parameters in laser sintering (SLS/PBF-LB/P), specifically for the glass bead-reinforced polypropylene and polyamide materials used. In addition, measurement data is recorded and evaluated directly from the 3D printer. High-resolution sensor data is collected, which serves as the basis for AI-supported process monitoring and error detection. The data obtained enables the printing process to be controlled in real time, thus ensuring consistently high component quality.
The data, findings, and methods developed in the project are being used to extend process monitoring and quality control to other materials and manufacturing processes. This will enable other materials to be analyzed and optimized more efficiently in the additive manufacturing process in the future. In addition, the results create a basis for broader industrial application, particularly in the series production of functional plastic components.
Partner quotes
„Laser sintering with plastics... is... not an established manufacturing technology suitable for series production... we have set ourselves the goal... of digitizing the entire process chain...“ – Martin Bayer, Leotech
„The digital process chain and loss-free information flow are critical success factors...“ – Nikolas Zimmermann, Fraunhofer IAO
„At Porsche, we see great potential in laser sintering with plastics and in the digitalization of the process chain.” – Ralph Renz, Projektleiter Porsche