One of the most common industrial 3D printing processes is laser powder bed fusion. It is mainly used for complex, heavy-duty components in aerospace, medical technology, and toolmaking. Over a period of six years, researchers led by the University of Duisburg-Essen have been working on improving processes and powders. The DFG-funded priority program Materials for Additive Manufacturing has now been successfully completed. The results provide a unique reference for science and industry. They are freely accessible via data from an interlaboratory study and in a special issue of the journal Advanced Engineering Materials.
In laser powder bed fusion (LPBF), a laser selectively melts thin layers of metal or polymer powder. This creates the component layer by layer. In order to systematically improve and standardize materials and additive processes, the German Research Foundation (DFG) established the priority program SPP 2122 in 2019. Under the direction of Prof. Dr. Stephan Barcikowski, Technical Chemistry at the University of Duisburg-Essen (UDE), more than 30 teams have since conducted research ranging from customized metal and polymer starting powders to functionalization with nanoparticles and detailed process characterization.
The interlaboratory study has resulted in the largest open dataset of its kind: 32 international laboratories produced, standardized, components from metallic and polymer powders – with and without nanoparticle modifications – in order to systematically compare the influence of material properties, machine parameters, and process control.
“The interlaboratory study is a milestone for science and industry, as it provides the first globally comparable data on highly complex manufacturing processes across different material classes,” says Dr. Anna Ziefuß, head of the Surface Chemistry and Laser Processing group at the UDE. “The results of the study, together with the contributions in the special issue, provide insights into the entire process chain – from material design and particle properties to final component performance.”
Based on the results, reliable standards can be developed, processes optimized in a targeted manner, and new materials brought into application more quickly. “Our goal was to present both fundamental understanding and practical solutions – and both completely open access,” says Ziefuß. This has been achieved: The data from the interlaboratory study will be available from November 11, 2025. The special issue Materials for Additive Manufacturing – Final Outcomes of SPP 2122 has already been published: https://advanced.onlinelibrary.wiley.com/toc/15272648/2025/27/14