Additive manufacturing
Additive manufacturing processes offer great potential with regard to geometrically complicated structures to be manufactured. We are researching new methods for modelling and design of such manufacturing processes. In particular, we are working on Laser Powder Bed Fusion (LPBF) and Fused Filament Fabrication (FFF). Special attention is focused on the observation of the process on different scale levels in order to predict the locally different as well as complex structural properties due to the underlying material properties as well as process control. Furthermore, we deal with the modeling of locally occurring interfaces.
Research focus
- Simulation of the printing process and prediction of the resulting temperature history at component level
- Warpage simulation based on the determined temperature history on component level
- Modeling of the FFF at the meso level for virtual characterization of the local properties of the printed structure
- Process hybridization
- Interfacial modeling
Research projects |
ContactM.Sc. Felix Frölich M.Sc. Lukas Hof |
Selected publications in the research field
Investigation of the thermoviscoelastic behavior of a closed-cell polymer structural foam under pressure for processing in hybrid LCM processes
Dietrich, S.; Dohmen, C.; Frölich, F.; Jackstadt, A.; Wittemann, F.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials. Vol 2 Material Science. Ed.: C. Binetruy, 548–554, European Society for Composite Materials (ESCM)
Dietrich, S.; Dohmen, C.; Frölich, F.; Jackstadt, A.; Wittemann, F.; Kärger, L.
2024. Proceedings of the 21st European Conference on Composite Materials. Vol 2 Material Science. Ed.: C. Binetruy, 548–554, European Society for Composite Materials (ESCM)
Entwicklung eines Simulationsmodells zur Strangablage in der Materialextrusion mit der Smoothed Particle Hydrodynamics Methode. master’s thesis
Hof, L.
2022, November 2. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000172570
Hof, L.
2022, November 2. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000172570
Homogenization of the Anisotropic Thermal Conductivity of Mesostructures in Material Extrusion
Hof, L.; Frölich, F.; Wittemann, F.; Kärger, L.
2024, July 2. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Hof, L.; Frölich, F.; Wittemann, F.; Kärger, L.
2024, July 2. 21st European Conference on Composite Materials (ECCM 2024), Nantes, France, July 2–5, 2024
Evaluation of mechanical properties characterization of additively manufactured components
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A. L.; Wittemann, F.; Kärger, L.; Liebig, W. V.
2024. Progress in Additive Manufacturing. doi:10.1007/s40964-024-00700-2
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A. L.; Wittemann, F.; Kärger, L.; Liebig, W. V.
2024. Progress in Additive Manufacturing. doi:10.1007/s40964-024-00700-2
Modeling time-dependent anisotropy in MEX component-scale process simulation
Di Nardo, M. E.; Frölich, F.; Kärger, L.; Carlone, P.
2024. Material Forming: ESAFORM 2024, 603–612, Materials Research Forum LLC. doi:10.21741/9781644903131-67
Di Nardo, M. E.; Frölich, F.; Kärger, L.; Carlone, P.
2024. Material Forming: ESAFORM 2024, 603–612, Materials Research Forum LLC. doi:10.21741/9781644903131-67
Electromechanical optimization of high reluctance torque variable flux machines under structural mechanical constraints
Kesten, J.; Armbruster, D.; Frölich, F.; Kärger, L.; Bonten, C.; Doppelbauer, M.
2024. Elektromechanische Antriebssysteme 2023 - Electromechanical Drive Systems 2023 Tagungsband der 9. Fachtagung (VDE OVE) 8. und 9. November 2023 in Wien, Ed.: Energietechnische Gesellschaft im VDE (ETG), 189–194, VDE Verlag
Kesten, J.; Armbruster, D.; Frölich, F.; Kärger, L.; Bonten, C.; Doppelbauer, M.
2024. Elektromechanische Antriebssysteme 2023 - Electromechanical Drive Systems 2023 Tagungsband der 9. Fachtagung (VDE OVE) 8. und 9. November 2023 in Wien, Ed.: Energietechnische Gesellschaft im VDE (ETG), 189–194, VDE Verlag
Design concept of a repairable YASA axial flux machine with a hybrid cooling system
Schäfer, A.; Baranowski, M.; Springmann, M.; Hof, L.; Frölich, F.; Peter, A.; Parspour, N.; Fleischer, J.; Middendorf, P.; Kärger, L.; Michalowski, A.
2023. 12th International Conference on Power Electronics, Machines and Drives (PEMD 2023), 119–128, Institution of Engineering and Technology (IET). doi:10.1049/icp.2023.1987
Schäfer, A.; Baranowski, M.; Springmann, M.; Hof, L.; Frölich, F.; Peter, A.; Parspour, N.; Fleischer, J.; Middendorf, P.; Kärger, L.; Michalowski, A.
2023. 12th International Conference on Power Electronics, Machines and Drives (PEMD 2023), 119–128, Institution of Engineering and Technology (IET). doi:10.1049/icp.2023.1987
Development of a test-method for characterization of the orientation dependent material properties of FFF structures
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A.; Kärger, L.; Liebig, W. V.
2023, August 3. 23rd International Conference on Composite Materials (ICCM 2023), Belfast, United Kingdom, July 30–August 4, 2023
Frölich, F.; Bechtloff, L.; Scheuring, B. M.; Heuer, A.; Kärger, L.; Liebig, W. V.
2023, August 3. 23rd International Conference on Composite Materials (ICCM 2023), Belfast, United Kingdom, July 30–August 4, 2023
Thermal Modeling of Laser Powder Bed Fusion during Printing on Temperature-Unstable Materials Considering Local Sintering
Frölich, F.; Kärger, L.
2022. Key Engineering Materials, 926, 331–340. doi:10.4028/p-uq57va
Frölich, F.; Kärger, L.
2022. Key Engineering Materials, 926, 331–340. doi:10.4028/p-uq57va
Design Approach for a Novel Multi Material Variable Flux Synchronous Reluctance Machine without Rare Earth Magnets
Kesten, J.; Frölich, F.; Wittemann, F.; Knirsch, J.; Bechler, F.; Kärger, L.; Eberhard, P.; Henning, F.; Doppelbauer, M.
2022. 2022 International Conference on Electrical Machines (ICEM), Valencia, Spain, 05-08 September 2022, 2304–2310, Institute of Electrical and Electronics Engineers (IEEE). doi:10.1109/ICEM51905.2022.9910780
Kesten, J.; Frölich, F.; Wittemann, F.; Knirsch, J.; Bechler, F.; Kärger, L.; Eberhard, P.; Henning, F.; Doppelbauer, M.
2022. 2022 International Conference on Electrical Machines (ICEM), Valencia, Spain, 05-08 September 2022, 2304–2310, Institute of Electrical and Electronics Engineers (IEEE). doi:10.1109/ICEM51905.2022.9910780
Challenges in characterization of polylactic acid (PLA) for thermomechanical material modeling in material extrusion
Frölich, F.; Dörr, D.; Jackstadt, A.; Kärger, L.
2022, July 4. 11th European Solid Mechanics Conference (2022), Galway, Ireland, July 4–8, 2022
Frölich, F.; Dörr, D.; Jackstadt, A.; Kärger, L.
2022, July 4. 11th European Solid Mechanics Conference (2022), Galway, Ireland, July 4–8, 2022
Hybrid material additive manufacturing: interlocking interfaces for fused filament fabrication on laser powder bed fusion substrates
Englert, L.; Heuer, A.; Engelskirchen, M. K.; Frölich, F.; Dietrich, S.; Liebig, W. V.; Kärger, L.; Schulze, V.
2022. Virtual and Physical Prototyping, 17 (3), 508–527. doi:10.1080/17452759.2022.2048228
Englert, L.; Heuer, A.; Engelskirchen, M. K.; Frölich, F.; Dietrich, S.; Liebig, W. V.; Kärger, L.; Schulze, V.
2022. Virtual and Physical Prototyping, 17 (3), 508–527. doi:10.1080/17452759.2022.2048228