OpAL - Optimization, Additive Manufacturing and Lightweight Engineering

The requirements of climate and environmental protection and the scarcity of resources present particular challenges for small and medium-sized enterprises (SMEs). In addition, competitive pressure and volatile market dynamics demand continuously growing innovative strength and flexibility. The triad of optimization, additive manufacturing and lightweight engineering is intended to contribute to overcoming these challenges.

In the product development process, state-of-the-art computer-aided engineering (CAE) methods are used. The design is usually produced with the aid of 3D CAD programs. Finite element analysis is one of the established simulation methods. This allows large parts of the process to be digitized, optimized and, in some cases, automated. The profitable integration of these methods and the associated possibility of early error detection reduce development times and costs.

Additive manufacturing (3D printing) makes it possible to raise unused potential. For example, conventional manufacturing processes (milling, casting, injection molding, etc.) are associated with manufacturing restrictions, such as the ability to remove the component from the mold after casting. This severely restricts the shape of the component. Additive manufacturing works without tools. This results in enormous flexibility, which opens up new freedom in the design of components. If additive manufacturing is used optimally, the result is components with similar stiffness and significantly reduced mass compared to conventional manufacturing. In symbiosis with various lightweight design strategies, this not only saves material, but also reduces energy consumption and greenhouse gas emissions during operation. In addition, very small quantities can be flexibly and economically produced at short notice.

The "OpAL" project

Since the application of methods from the fields of optimization, additive manufacturing and lightweight engineering is not trivial, application-oriented knowledge transfer measures are carried out in the OpAL project, especially for regional SMEs and their employees. Derived from the triad of optimization, additive manufacturing and lightweight engineering, there are six thematic blocks together with the product development process, software and technology as well as testing and demonstration.

By working on different use cases and with individual solutions for concrete problems, the project partners acquire a deep and lasting understanding of the project contents. Thus, a regional network of SMEs around innovative product development with special consideration of sustainability aspects is created during the project.

Additive Manufacturing for testing technology and special applications at Schmidt-Engineering GmbH  

As part of the knowledge transfer measure, project partner Weinmann Prüftechnik by Schmidt-Engineering provided information in the first part about their innovative and creative use of 3D printing in the product development process. The company specializes in standard-compliant testing technology for special applications. The product range here extends from test stands for the fatigue strength of bicycles to those for the certification of office and upholstered furniture and mattresses. In addition to prototype construction, additive manufacturing is also used whenever components manufactured using conventional production methods can be replaced at low cost. For example, additively manufactured components are integrated as standard into test benches as adapters, spacers and guides.

Inspired by the possibilities of 3D printing, the second part of the knowledge transfer measure aimed to deepen practical experience. A test gauge, which was manufactured several times using different printing processes, settings and materials, was tested on a mechanical test rig to determine its stiffness. Together with the weight of the component, the printing and material costs and the printing time, an initial picture was obtained of the properties and advantages and disadvantages of the various printing processes. These investigations will be continued in the future by taking a closer look at the dimensional accuracy and surface quality of the components.

This project is funded by the European Social Fund (ESF).