Fraunhofer ILT will show at Formnext how you can print sensors directly on 3D printed components. A second innovation is the 3D printing of sensors in an LPBF machine. These innovations are important for predictive maintenance, among other things.
Sensors play an essential role in the further development of Industry 4.0. After all, they provide the data needed to make predictions or adjust processes. Until now, the sensors are often placed on the surface of a part. To measure the load more accurately, a sensor in the part is better.
On the left the sensors that are printed during printing with a special process, on the right the finished tool holder.
Sensor printed on draaram
Fraunhofer ILT in Aachen is taking this step with the new technology that it will be showing at Formnext next month. A first example is a force sensor printed on a wishbone of a passenger car. The sensor is barely 200 µm thick, including protection and connections. The researchers developed this sensor for the racing world and continuously collects data about the forces on the wishbone. The sensor warns in time of a defect. “The force sensor registers the smallest cracks that appear before they lead to failure of the part,” says Samuel Moritz Fink, group head of Dünnschichtschilderahren at the Aachen Research Institute. Other types of sensors, for example for temperature, vibrations or voltages, are also possible.
Integration into LPBF process
The second innovation on the Fraunhofer ILT stand is the seamless integration of sensors during the additive manufacturing process. The technology developed for this purpose is intended for the Laser Powder (LPBF) process. The Fraunhofer researchers demonstrate this technology using an additively manufactured tool holder for milling. The printing process is interrupted to create strain gauges using a digital functional printing process and laser-based thermal post-treatment. The normal printing process then continues.
Broad field of application
This combination of structural and functional printing and laser thermal post-treatment makes it possible to make components with integrated sensor technology. This not only allows the sensors to be placed more optimally in a workpiece, but also improves the protection of these sensors against mechanical environmental influences. According to the Fraunhofer ILT, applications are countless: in addition to mechanical engineering, this can also be applied in the automotive industry and aerospace.
Formnext will take place in Frankfurt from November 7 – 10