Technological Challenges for Automotive Series Production in Laser Beam Melting

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Haeckel, Felix
Meixlsperger, Maximilian
Burkert, Torsten

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University of Texas at Austin


Compared to traditional production methods, Additive Manufacturing enables a tool free production leading to higher flexibility, freedom of design and lightweight potential. For these reasons the BMW Group is proceeding from the production of prototypes to the direct series production of parts. For metal components, the process of selective Laser Beam Melting is able to realize these potentials. Aside from the economic issues, technological challenges also have to be met. Among them is achieving consistent part quality in the production of same parts. To achieve technical specifications compliant in series production, a defined process stability and reproducibility of the part properties is needed. This reproducibility is investigated for the process of selective Laser Beam Melting. Also variables which have the biggest impact on the part quality throughout a simulated series production are being examined. Thus the reproducibility of the process can be quantified. To guarantee a high and stable part quality in the future, approaches are being developed to monitor or systematically prevent influences, which are found to have a negative effect on the process quality.


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