Material Design as a Strategic Key to Additive Manufacturing
Additive manufacturing has made enormous progress in recent years. However, the decisive step – the targeted development of materials for AM processes – is still in its infancy in many places. The new training course “Werkstoffdesign für die additive Fertigung” addresses precisely this issue and teaches a systematic, simulation-based approach that closely integrates the material, process, and component levels. 

The focus is on physics-based material design. This approach reduces lengthy trial-and-error loops and enables informed decisions to be made early on in the development process. Under the lead of Dr.-Ing. Florian Hengsbach, Prof. Dr.-Ing. Thomas Niendorf, and Prof. Dr.-Ing. habil. Mirko Schaper, participants learn how material properties can be precisely tailored to specific requirements – a skill that is becoming increasingly important across industries. 

From Metal Powder to Finished Component: A Comprehensive View of the Process
The course begins with the basis of every AM process: metal powder. Different atomization methods, particle size distribution, flow behavior, and chemical purity are classified and evaluated based on their relevance to process stability. 

This is followed by a detailed look at selective laser melting (PBF-LB/M). Based on the system architecture and the most important process parameters – from laser power to component orientation – the chairs show how these control variables influence microstructure, porosity, and surface quality. The goal is to gain a deep understanding of the physical relationships in the melt pool and during solidification. 

CALPHAD, FEM, and Digital Twins: Material Design Becomes Predictable
One focus is on mechanistic material design. CALPHAD, thermodynamic models, and FEM simulations are not used here as abstract theory, but as practical tools for predicting microstructural states, phase transformations, and fatigue behavior. 

Digital twins and machine learning expand this approach with data-driven possibilities that significantly accelerate development cycles. Graphical and hierarchical design methods help to weigh competing requirements — such as strength, ductility, and corrosion resistance —in a structured manner. 

Case studies illustrate how companies such as Tesla, SpaceX, and Apple are already using simulation-based material design. The examples show how new alloys can be quickly validated and specifically adapted to extreme requirements, such as for lightweight components, high-temperature applications, or complex functional parts. 

The new training course combines metallurgical expertise, process understanding, and modern simulation techniques into a rigorous concept for the development of additively manufactured materials. Those who want to use additive manufacturing strategically will find a comprehensive toolbox here — scientifically sound and taught in a practical manner. 

Register now!