Sustainable 3D printing: Thuringian research project optimises material extrusion for metal components

The market for the additive manufacturing of metals is growing continuously, with powder bed-based processes dominating in particular. These enable the printing of complex geometries with high precision, but the acquisition costs of the systems are high. Filament-based 3D printing offers a more cost-effective alternative, which is now set to become more sustainable and recyclable thanks to a research project from Thuringia.

As part of the ‘MexWer’ project, three research institutes from Thuringia – the Thuringian Institute for Textile and Plastics Research (TITK), the Günther Köhler Institute for Joining Technology and Materials Testing (ifw) and the Gesellschaft für Fertigungstechnik und Entwicklung (GFE) – are developing an optimised process chain for the additive manufacturing of metallic tool components using material extrusion. The aim is to increase the resource efficiency of the manufacturing process and promote the use of sustainable materials.

TITK is developing special filaments that contain up to 90 per cent metal powder. After the printing process, the plastic content is first removed using solvents and then thermally, before the component is turned into a dense metal object in a sintering process. This innovative method promises to be a resource-saving alternative to conventional processes, which often rely on toxic solvents or complex oven processes.

“3D printing filaments available on the market require either toxic and flammable solvents for debinding or very complex furnace processes for sintering,” says Edgar Merting, project manager at TITK in Rudolstadt. The aim is therefore to establish a sustainable and recyclable alternative. “With our filaments, solvent debinding can take place before the furnace process using water or water-based solvents,” says Merting.

The project also aims to strengthen regional supply chains and thus contribute to the development of local production networks. TITK will present further details about the project at Fakuma 2024 in Friedrichshafen. The trade fair will take place from 15 to 19 October, where TITK will be represented together with its subsidiary OMPG at the Thuringia stand (Hall B5, Stand B5-110).