Printed Effects Department (PEF)

Projects

• AM2H2 – Additive manufacturing of multi-material components for sustainable energy conversion (funded by the ERDF)
  This project aims to increase the efficiency of ammonia splitters through the use of multi-material, additively manufactured components. The focus is on developing a multi-objective optimization algorithm to take thermal, mechanical, and chemical requirements into account, process development for multi-material connections using the PBF-LB/M process, and scaling the components from test specimens to a demonstrator that can be used industrially.

• Ellipse – Development methodology for laser beam-melted lightweight structures with integrated particle dampers for vibration reduction (DFG)
  In this research project, which is being carried out in collaboration with the Institute of Dynamics and Vibrations (IDS) at LUH, multi-material particle dampers for vibration reduction are simulated, additively manufactured using PBF-LB/M, characterized, and validated on the demonstrator. The goal is to conduct a comprehensive physical evaluation of laser beam-melted particle dampers. Based on this, a development tool will be created for designing structural components with integrated particle dampers to optimize stiffness, mass, and damping.

   

• Optiwas – Methodology for optimizing the interactions between additive and subtractive manufacturing (DFG)
  This project, which is being carried out in collaboration with the Institute for Manufacturing Technology and Machine Tools (IFW) at LUH, aims to explore the potential of additive machining combinations. Data and information will be collected across several product generations and then aggregated into knowledge about the process combination. With the help of additive design freedoms, new solutions for stiffening and improving the clamping of additively manufactured components will be sought. This will be analyzed and validated using a demonstrator.

   

• Adaptation of a CHP unit using additively manufactured components for future hydrogen operation (NBank)
  As part of the project, IPeG is collaborating with its partners ITV and ATRON GmbH. Together, they aim to redesign engine components for a combined heat and power plant (CHP) using additive manufacturing. The goal is to optimize the efficiency and increase the robustness of engines for CHPs in climate-friendly hydrogen operation.

• Powder bed-based additive multi-material manufacturing
  This research project deals with the design of multi-material components for additive manufacturing, in particular using the process of powder bed-based melting of metals by means of a laser beam (PBF-LB/M). Based on a series of experiments, both general and machine- and material-specific recommendations for the additive manufacturing of multi-material components are to be developed. The aim is to resolve conflicting design objectives in component design through voxel-by-voxel material deposition and to produce geometrically and functionally optimized structures with locally adapted material properties.

   

• Scale-independent additive manufacturing
  This research project investigates the additive repair of large metal components using powder bed-based melting of metals by means of a laser beam (PBF-LB/M). At IPeG, we have access to the patented MESSIAH system, which is designed for component heights of up to 2.5 meters and enables repairs to be carried out on corresponding components. Examples of applications include turbine blades and gas burners, where damaged areas, especially at the tips, are specifically rebuilt. A new process chain is being developed for this purpose, which is specifically geared to the requirements of repair planning, sealing concepts, thermal management, and the fixation of components during the process.

   

• Vibration-damped optics
  This research project involves the development and investigation of innovative optical systems with integrated vibration damping structures. The aim is to significantly increase optical performance and stability under real environmental conditions, such as those encountered in space travel. By combining additive manufacturing and particle-damped structures, new approaches for reducing vibration influences on sensitive optical components are being developed and experimentally validated. The methods and structures developed will be used both for the design of new optomechanical systems and for the retrofitting of existing applications.

   

• Potential and limitations of laser powder cladding in additive manufacturing for industrial aviation applications
  As part of this research project, which is being carried out in collaboration with MTU Maintenance Hannover, a novel approach to additive repair of high-performance components in the aviation industry is being developed. The laser powder deposition welding (L-DED) process with frequency doubling is being investigated, initial application findings are being gained, and specific process parameters are being optimized. The aim is to seamlessly integrate L-DED technology into existing process chains, identifying, analyzing, and further developing interfaces to upstream and downstream manufacturing processes.

Competencies

• Publications (excerpt)
   

  ⦁    Lachmayer, R., Ehlers, T., & Lippert, R. B. (2022). Entwicklungsmethodik für die Additive Fertigung. Springer. doi.org/10.1007/978-3-662-65924-3
  ⦁    Lachmayer, R., Ehlers, T., & Lippert, R. B. (2024). Design for Additive Manufacturing (1st ed.). Springer Berlin. link.springer.com/book/9783662684627
  ⦁    Ehlers, T., Meyer, I., Oel, M., Bode, B., Gembarski, P. C., & Lachmayer, R. (2023). Effect-Engineering by Additive Manufacturing. In R. Lachmayer, B. Bode, & S. Kaierle (Eds.), Innovative Product Development by Additive Manufacturing 2021 (pp. 1–19). Springer International Publishing. doi.org/10.1007/978-3-031-05918-6_1
  ⦁    Meyer, I., Oel, M., Ehlers, T., & Lachmayer, R. (2023). Additive manufacturing of multi-material parts – Design guidelines for manufacturing of 316L/CuCrZr in laser powder bed fusion. Heliyon, 9(8), e18301. doi.org/10.1016/j.heliyon.2023.e18301
  ⦁    Oel, M., Rossmann, J., Bode, B., Meyer, I., Ehlers, T., Hackl, C. M., & Lachmayer, R. (2023). Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth. Additive Manufacturing Letters, 7, 100165. doi.org/10.1016/j.addlet.2023.100165
  ⦁    Meyer, I., Messmann, C. O., Ehlers, T., & Lachmayer, R. (2025). Additive manufacturing of multi-material parts – Effect of heat treatment on thermal, electrical, and mechanical part properties of 316L/CuCrZr. Materials & Design, 252, 113783. doi.org/10.1016/j.matdes.2025.113783

   

  ⦁    Meyer, I., Glitt, L., & Ehlers, T. (2025). Additive Manufacturing of Metallic Multi-Material Parts: Local Conductivity Adjustment through Functionally Graded Material Transitions of 316L and CuCrZr. In R. Lachmayer, M. Oel, & S. Kaierle (Eds.), Innovative Produktentwicklung durch additive Fertigung (pp. 231–246). Springer. doi.org/10.1007/978-3-662-69327-8_15

  ⦁    Niedermeyer, J., Schlenker, F., Huuk, J., Ehlers, T., & Denkena, B., Lachmayer, R. (2024). Design guidelines for additively manufactured stiffening structures to reduce vibrations in milling. Procedia CIRP.
  ⦁    Niedermeyer, J., Ehlers, T. , Lachmayer, R. (2023). Potential of additively manufactured particle damped compressor blades: A literature review. In Procedia CIRP; Volume 119; S. 570–575. doi.org/10.1016/j.procir.2023.02.151 
  ⦁    Oel, M. (2024). Mode selective damping behavior of additively manufactured beam structures. Progress in Additive Manufacturing, 1–12. doi.org/10.1007/s40964-024-00838-z
  ⦁    Ehlers, T., Tatzko, S., Wallaschek, J., & Lachmayer, R. (2021). Design of particle dampers for additive manufacturing. Additive Manufacturing, 38, 101752. doi.org/10.1016/j.addma.2020.101752
  ⦁    Niedermeyer, J., Oel, M., Meyer, I., Stauß, T., Mesecke, L., Maalaoui, M., Gerhards, P., Eibl, F., & Ehlers, T. (n.d.). Konzept einer additiven Großfertigungsanlage zur skalenunabhängigen additiven Fertigung und Reparatur. doi.org/10.1007/978-3-662-69327-8_1
  ⦁    Mesecke, L., Meyer, I., Oel, M., & Lachmayer, R. (n.d.). Challenges and Potentials for Additive Manufacturing of Hydrogen Energy Components: A Review. doi.org/10.1016/j.ijhydene.2025.02.441
   

• Doctoral theses
   

  ⦁    Ehlers, T. (2023). Auslegung partikelgedämpfter Strukturbauteile für die Additive Fertigung [DoctoralThesis, Hannover: Institutionelles Repositorium der Gottfried Wilhelm Leibniz Universität]. doi.org/10.15488/13789
  ⦁    Ganter, N. V. (2023). Reparatur und Modernisierung metallischer Bauteile durch pulverbettbasiertes Schmelzen mittels Laserstrahl [DoctoralThesis, Hannover : Institutionelles Repositorium der Leibniz Universität Hannover]. doi.org/10.15488/14769
  ⦁    Bode, B. (2024). Entwurf von thermisch und mechanisch belasteten Bauteilen durch Lasttrennung. TEWISS Verlag. ⦁    https://doi.org/10.51202/97839⦁    5⦁    9009300