HoTT3D – High Temperature Tooling, 3D-printed

Development of a methodology to compensate the thermal induced deformation in 3D-printed tooling during the manufacturing of fiber reinforced components.

Project Partners
Composyst GmbH

Duration
01.01.2025 – 31.12.2026

Funding authority
Federal Ministry for Economic Affairs and Climate Action

Motivation
Due to their high strength combined with low weight, components made from fiber-reinforced composites are crucial in the aerospace, automotive, and sports industries. Tooling costs are the main driver behind the high prices of such components. Compared to conventional manufacturing methods, 3D printing offers a faster and more cost-effective way to produce tools for the fabrication of fiber-reinforced parts. However, the layer-by-layer construction of the tools results in highly anisotropic material properties. Within the framework of the research project HoTT3D, a methodology is to be developed that enables the prediction and compensation of the complex thermal deformation of tools 3D-printed utilizing Fused Filament Fabrication (FFF).

Method
First, a commercially available material is selected that meets the requirements for a 3D-printed tool intended for high-temperature applications. The thermal properties of this material are then systematically investigated, with a particular focus on how different process strategies in Fused Filament Fabrication (FFF) influence these properties. The aim is to establish a robust data foundation for predicting thermally induced deformations. In addition, additive manufacturing potentials—such as conformal cooling channels and integrated temperature sensors—will be explored and evaluated. Based on the experimental findings, a simulation model will be developed to predict the thermal deformation of additively manufactured tools. By compensating for these deformations during the design phase, it will ultimately be possible to produce dimensionally accurate composite parts.

Acknowledgement
The chair would like to thank the Federal Ministry for Economic Affairs and Energy for funding the project HoTT3D under the "ZIM:Produktionsforschung" program. (Funding reference: KK5135832KU4)

Contact Persons
Julian Lachner, M.Sc.; Dipl.-Ing. Thomas Wettemann