Fraunhofer Project Group Process Innovation
Fraunhofer Project Group Process Innovation

High Speed Sintering (HSS)

The innovative additive manufacturing process "High Speed Sintering (HSS)" enables the industrial production of polymer components with highly complex geometries while maintaining high quality and cost-effectiveness. In addition to its high reproducibility and the ability to use a broad range of polymers, the scalability of the HSS process offers significant potential for industrial applications.

The layer-by-layer process of HSS is as follows: First, a recoater applies a layer of polymer powder to the build platform (powder application). Then, an infrared-absorbing ink is selectively applied to the areas that are to be fused (ink application). Subsequently, an infrared lamp passes over the powder bed surface (selective energy input). The ink absorbs the infrared radiation, raising the temperature of the polymer powder contacted with ink above its melting point. This partially melts the polymer powder. These steps are repeated until the layer-by-layer process is completed (finishing).

Competences

Material Qualification

HSS enables the processing of a wide range of polymers, including some that were previously not suitable for additive manufacturing. To qualify your polymer for HSS, we support you from the initial proof of concept through a multi-stage parameterization process to the collaborative, process-specific adaptation of the polymer powder.

Process and Component Development

By adjusting the selective energy input at voxel level and using functional inks, the HSS enables the production of components from functionally graded material. This enable the production of components with continuous and discontinuous mechanical, tribological, or electrical property gradients, for example. We support you from the design phase through material selection to the design of the manufacturing process for functionally graded components.

Facility Development

There is still great potential for HSS for innovation and optimization in the field of equipment systems, especially regarding productivity, process-related functionalization of components, and the range of processable materials. To tap into these potentials, we optimize individual components for existing HSS systems and develop complete application-specific equipment systems.

HSS Material Network

To expedite the qualification of new polymer materials for High Speed Sintering (HSS), the Fraunhofer IPA, the University of Bayreuth, and voxeljet AG have initiated the HSS Material Network. The goal of the HSS Material Network is to pool existing expertise in order to provide flexible support to companies in the development, parameterization, and certification of polymer materials. Only adjustment between equipment technology, manufacturing processes, and polymer materials allows the production of components with high quality. The HSS Material Network also assists companies in marketing their polymer materials, from proof of concept and benchmarking to integration into serial production.

Referenzen

Proof of Concept

SABIC’s experimental PET powder

The Proof of Concept demonstrates the fundamental processability of PET in HSS for the first time. The tests also revealed process-, equipment- and material-specific optimizations that enable PET components to be manufactured in HSS in a way that is suitable for industrial use.

Proof of Concept

iglidur® i3 PL, igus® GmbH

Based on an initial parameterization of the wear-optimized material, plain bearings and gears with excellent tribological properties were manufactured. Due to its excellent processability and resulting high-quality parts, the polymer powder proved to be highly suitable for HSS in the Proof of Concept.

Proof of Concept

ROLASERIT® PP01, AM POLYMERS GmbH

The Proof of Concept demonstrates the good processability of PP powder in HSS. Even in this early stage of parameterization, parts with good properties were successfully manufactured.

Benchmarking

DiaPow HDPE HX 11, Diamond Plastics GmbH

HDPE is one of the most commonly used polymers due to its properties. Adequate processing through additive manufacturing, such as laser sintering (LS), has been challenging because of HDPE's tendency to degradation at high energy inputs. However, the materials-specific HSS process enables the production of HDPE components with excellent mechanical properties and high surface quality.

Benchmarking

PowderSintTM TPU Soft UE 354, Launhardt GmbH

Additive manufacturing of very soft TPU parts using powder bed-based processes presents significant challenges due to reduced powder flowability as Shore hardness decreases. The HSS process, specifically adapted for soft TPU powder, allows for suitable processing and the production of high-quality components.

Qualifizierung

ROLASERIT® TPU, AM POLYMERS GmbH

The components produced using the developed HSS process with TPU exhibit properties that are on par with or even surpass those achieved in laser sintering. For instance, high elongation at break. Furthermore, hardness within a component can be adjusted on a voxel level, ranging from 60 to 82 Shore A.

HSS- Laboratory

The core element of the HSS laboratory is the High Speed Sintering (HSS) machine voxeljet VX200 HSS. Its open software and hardware allow the individual adjustment of all process parameters and the free programming of process steps. As a result, in combination with the existing equipment for pre- and post-processing, it provides optimal conditions for any research and development work along the entire HSS process chain. In addition, an extensive range of analysis and measurement equipment is available for determining all powder and component properties relevant to material qualification.