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

M.Sc. Felix Frölich
Tel.: +49 721 608-45361
Email: felix.froelich∂

M.Sc. Lukas Hof
Tel.: +49 721 608-45385
Email: lukas.hof∂

Process simulation of fused filament fabrication (top) and laser powderbed fusion (bottom)

Selected publications in the research field

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
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
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
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
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