Additive manufacturing (AM) processes, also known as "3D printing", allow the economical production of individualised components with a high degree of design freedom. This makes them particularly important in industries with very low quantities and many prototype tests, such as medical engineering. In orthopaedics, for example, it is often helpful to adapt splints or orthoses to the patient's individual anatomy and functional requirements. Due to their good processability, adjustable properties and low density, polymer-based materials are increasingly applied. However, the goal-oriented development of such customised polymer components requires knowledge of the according processes and materials and can be effectively supported by computer-aided CAE methods.

In the course, students learn about additive manufacturing (AM) of individualised polymer components and apply their competences in a development project during the semester. The course first provides an overview of established AM process technologies and uses the example of extrusion processes to work out the interaction of material, process settings and design. Special requirements of medical technology for component development and material selection are presented in separate lectures. This is followed by an application-oriented introduction to the practical component design of printed polymer structures using the finite element method (FEM). FE-based topology optimisation is presented as a particularly suitable tool to devise efficient mechanical structures. The CAE design methods are specifically deepened in practice in exercises. With this knowledge of processes, materials and methods, the students finally solve an individual development project from the field of orthotics in small groups.

Main topics:

• Overview of additive manufacturing processes
• Process-material-component interaction
• Polymers in additive manufacturing:

Fundamentals of polymer science, material and component testing,

• Special aspects of additive manufacturing in medical technology (external guest contributions):

Selection of process and material, orthotics/prosthetics as an application case

• Computer-aided component design and optimisation
• (lectures and exercises)
• Semester project:
  Design, manufacture and testing of an AM component from the field of "medical technology

Learning objectives

The students can...

• ... name and describe different AM manufacturing technologies for polymer components and select them based on their characteristics (especially advantages/disadvantages and process limits).
• ... describe the development chain in additive manufacturing

(material selection, CAD, simulation/optimisation, slicer software) and implement it.

• ... describe the interaction of process parameters, material properties and design for polymer components at the example of extrusion processes.
• ... name and explain relevant additional medical technology aspects, e.g. sterilisability or allergy potential, in material and process selection
• ... explain essential concepts of the finite element method and topology optimisation
• ... use the finite element software "Abaqus" for component design and evaluate simulation results with regard to informative value and load-bearing capacity
• ... carry out a topology optimisation with the software Tosca, interpret its results and derive structural concepts.
• ... successfully realise an individual development project in the area of additive manufacturing in a goal-oriented manner.

Die Raumbelegung und der wöchentliche Veranstaltungstermin wird zu Beginn des Sommersemesters auf der Homepage des Instituts bekannt gegeben.

Aufgrund des gewünschten Betreuungsverhältnisses und der Institutsausstattung ist die maximale Anzahl der teilnehmenden Studierenden begrenzt. Die Anmeldung erfolgt über die Instituts-Homepage ab Anfang März.

Zusätzliche Übungen werden an weiteren 6 Terminen immer von 15:45 – 17:15 Uhr in R. 125, Geb. 70.04, Campus Ost stattfinden: 22.05., 28.05., 05.06., 26.06., 03.07., 09.07.2025.

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The room allocation and the weekly course dates are announced on the Institute's homepage at the beginning of the summer semester.

Due to the desired supervision ratio and the institute's equipment, the maximum number of participating students is limited.

Registration takes place via the Institute's homepage from the beginning of March.

Additional exercises will take place on 6 dates from 15:45 - 17:15 in room 125 at Building 70.04, Campus East:  22.05., 29.05., 05.06., 26.06., 03.07., 09.07.2025.