Embracing the Gap: A New Approach to Accelerate Metal 3D Printing
Thomas Beising, Simulation Engineer at ECOMAT partner TECHNIA, Picture: WFB/Rathke
The goal of the APFeL project ("Application-Oriented Process Control for Efficient Laser-Based Additive Manufacturing of Lightweight Components") is to accelerate metal 3D printing by developing new manufacturing strategies. In cooperation with partners such as TECHNIA and the Leibniz Institute for Materials Engineering – IWT, experts at Bremen’s ECOMAT are combining materials science, lightweight construction, and digitalization.
In metal additive manufacturing, pores — gas inclusions within the printed material — are typically viewed as process defects. Especially in critical industries like aerospace, components are inspected via X-ray imaging to detect such inclusions, as pores, often smaller than one millimeter, can impair a part's structural integrity and cause material failure.
It’s Not a Bug, It’s a Feature!
Porosity often arises when printing speeds are increased. Could this phenomenon be turned into an advantage? This is the central question driving the APFeL project, a collaboration between research institutions and industrial partners based in Bremen.
“Can we deliberately accept a certain level of porosity in low-load regions of a part to speed up the overall printing process?” explains Thomas Beising, Simulation Engineer at ECOMAT partner TECHNIA.
Faster printing saves machine time — and thus costs — particularly important when operating expensive industrial 3D printers. To maintain mechanical integrity, the new strategy limits the use of high-speed printing to non-critical, low-stress regions of the part. The underlying idea: where loads are low, full material density is not required.
Simulation of low-stress regions, Picture: WFB/Rathke
An Alternative to Topology Optimization
This concept is somewhat reminiscent of topology optimization, where engineers digitally design components that use minimal material while maintaining maximum strength, often resulting in intricate, organic structures. Material is added only where mechanical loads demand it.
However, the APFeL approach takes a different path: instead of altering the original part geometry, it adapts the printing process itself. "Our method is ideal for components with fixed geometries where redesigning the part is not an option," says Beising. Within the project, TECHNIA is developing an algorithm that identifies low-stress regions, assigns them lower material property requirements, and verifies mechanical performance in automated simulation loops.
From Simulation to Practice
Initial simulations have produced promising results. Using a bicycle crank as a model, the team demonstrated:
- Up to 50% faster manufacturing
- 20% reduction in strength and 10% reduction in stiffness
- Approximately 10% lower material density
“We're achieving a significant increase in production speed with only minimal mechanical trade-offs. That’s extremely encouraging,” summarizes Beising.
The next step is to validate these findings in practice: the Bremen-based IWT is currently conducting test series using standardized specimens.
Bremen as a Hub for Lightweight Construction and Additive Manufacturing
APFeL also integrates further innovations around additive manufacturing and lightweight engineering, developed by other project partners, including Materialise, Fraunhofer IAPT in Hamburg, the 3N Competence Center in Werlte, and Inpeca from Aachen.
“In additive manufacturing, we benefit from cross-industry expertise — it's a perfect example of industrial technology transfer. That's why projects like APFeL are so important for driving innovation,” emphasizes Beising.
The project idea originated at a networking event at ECOMAT, highlighting the center’s role as a catalyst for collaboration: “ECOMAT provides an outstanding platform for such initiatives.”
Beising is alaways open to new ECOMAT projects, Picture: WFB/Rathke
A Personal Connection to Bremen
Beising, originally from the Black Forest, first came to Bremen for his studies in 2002. After working abroad, including in Vienna, he ultimately returned to the Hanseatic city: “I missed Bremen. I feel very much at home here — it’s a green, vibrant city with everything you need.” In 2015, he seized the opportunity to relocate permanently.
At the time, he was working for Prime Aerostructures, a Vienna-based SME later acquired by TECHNIA in 2024. Today, TECHNIA specializes in the digitalization of product development processes and offers the 3DEXPERIENCE platform across industries. Of TECHNIA’s 525 employees, 200 are based in Germany; in Bremen, Beising holds the fort alone. “Thanks to digital collaboration, we stay fully connected. I also serve as TECHNIA’s direct link to Bremen’s innovation ecosystem, with ECOMAT playing a key role.”
Looking ahead, Beising is excited to represent TECHNIA at ECOMAT events — and he welcomes a bit more interaction in everyday office life: “Many people at ECOMAT don’t even know I’m up here on the first floor. I’m always happy to have visitors or share a coffee in the cafeteria!”
About TECHNIA
Bringing new products to market is a complex, costly, and time-consuming endeavor. In competitive industries, efficiency and transparency are more critical than ever. TECHNIA provides digital solutions to simplify processes, accelerate innovation, and shorten time-to-market.
We can't always promise simplicity — but with the right combination of technology, expertise, and commitment, we reduce complexity to help businesses succeed.
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