TY - JOUR A1 - Ginés-Palomares, Juan-Carlos A1 - Facchini, Leonardo A1 - Wilbig, Janka A1 - Zocca, Andrea A1 - Stoll, Enrico A1 - Günster, Jens T1 - Melt Pool Stability during Local Laser Melting of Lunar Regolith with Large Laser Spots and Varying Gravity N2 - In order to increase the sustainability of future lunar missions, techniques for in-situ resource utilization (ISRU) must be developed. In this context, the local melting of lunar dust (regolith) by laser radiation for the production of parts and larger structures was investigated in detail. With different experimental setups in normal and microgravity, laser spots with diameters from 5 mm to 100 mm were realized to melt the regolith simulant EAC-1A and an 80%/20% mixture of TUBS-T and TUBS-M, which are used as a substitute for the actual lunar soil. In the experiments performed, the critical parameters are the size of the laser spot, the velocity of the laser spot on the surface of the powder bed, the gravity and the wettability of the powder bed by the melt. The stability of the melt pool as a function of these parameters was investigated and it was found that the formation of a stable melt pool is determined by gravity for large melt pool sizes in the range of 50 mm and by surface tension for small melt pool sizes in the range of a few mm. KW - Additive Manufacturing KW - Regolith KW - Laser melting KW - ISRU PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-639621 DO - https://doi.org/10.1016/j.amf.2025.200227 SN - 2950-4317 VL - 4 IS - 3 SP - 1 EP - 10 PB - Elsevier Ltd. AN - OPUS4-63962 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hoffmann, M. A1 - Schubert, Nils A1 - Günster, Jens A1 - Stawarczyk, B. A1 - Zocca, Andrea T1 - Additive manufacturing of glass-ceramic dental restorations by layerwise slurry deposition (LSD-print) N2 - This study is dedicated to the additive manufacturing of a feldspar glass-ceramic for dental applications by LSD-print (layerwise slurry deposition) technology, a variation of binder jetting using water-based ceramic slurries as feedstock. This technology was investigated for the manufacturing of single tooth restoration demonstrators with good aesthetic properties, and to compare the additively manufactured material with a commercial reference. Model restorations with > 99 % relative density were processed with a debinding and firing cycle of 45 min, however the whole process chain accounts for up to 30 hours. Significant differences between LSD-printed and reference materials were found for fracture strength, fracture toughness and Martens parameters. Printing orientation affected shrinkage and fracture strength, but not fracture toughness and Martens parameters. Nevertheless, the results suggest that the LSD-print technology processing the developed slurry is a promising option for manufacturing dental restorations meeting class 1a requirements according to DIN EN ISO 6871:2019–01. KW - Additive Manufacturing KW - 3D-printing KW - LSD-print KW - Dental ceramics KW - Glass-ceramic KW - Debinding KW - Firing KW - Sinter-crystallization PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-624768 DO - https://doi.org/10.1016/j.jeurceramsoc.2025.117235 VL - 45 IS - 7 SP - 1 EP - 13 PB - Elsevier Ltd. AN - OPUS4-62476 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Waske, Anja T1 - A unique authenticator for additively manufactured parts derived from their microstructure N2 - In the field of additive manufacturing, the ability to uniquely identify and authenticate parts is crucial for certification, logistics, and anti-counterfeiting efforts. This study introduces a novel methodology that leverages the intrinsic microstructural features of additively manufactured components for their identification, authentication, and traceability. Unlike traditional tagging methods, such as embedding QR codes on the surface [1] or within the volume of parts, this approach requires no alteration to the printing process, as it utilizes naturally occurring microstructural characteristics. The proposed workflow [2] involves the analysis of 3D micro-computed tomography data to identify specific voids that meet predefined identification criteria. This method is demonstrated on a batch of 20 parts manufactured with identical process parameters, proving capable of achieving unambiguous identification and authentication. By establishing a tamper-proof link between the physical part and its digital counterpart, this methodology effectively bridges the physical and digital realms. This not only enhances the traceability of additively manufactured parts but also provides a robust tool for integrating digital materials, parts databases, and product passports with their physical counterparts. T2 - Artificial Intelligence in MSE CY - Bochum, Germany DA - 18.11.2025 KW - Authentication KW - Additive Manufacturing KW - Non-destructive testing PY - 2025 AN - OPUS4-65204 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ginés-Palomares, Juan-Carlos A1 - Baasch, Julian A1 - Stapperfend, Simon A1 - Facchini, Leonardo A1 - Linke, Stefan A1 - Stoll, Enrico A1 - Günster, Jens T1 - Laser Melting vs. Laser Sintering: Large Area Heat Processing of Lunar South Pole Simulant N2 - A key component of future lunar missions is the concept of In-Situ Resource Utilization (ISRU), which involves the use of local resources to support human missions and reduce dependence on Earth-based supplies. This paper investigates the thermal processing capability of lunar regolith without the addition of binders, with a focus on large-scale applications for the construction of lunar habitats and infrastructure. The study used a simulant of lunar regolith found on the Schrödinger Basin in the South Pole region. This regolith simulant consists of 20 wt% basalt and 80 wt% anorthosite. Experiments were conducted using a high power CO2 laser to sinter and melt the regolith in a 80 mm diameter laser spot to evaluate the effectiveness of direct large area thermal processing. Results indicated that sintering begins at approximately 1,180 °C and reaches full melt at temperatures above 1,360 °C. Sintering experiments with this material revealed the formation of dense samples up to 11 mm thick, while melting experiments successfully produced larger samples by overlapping molten layers and additive manufacturing up to 50 mm thick. The energy efficiency of the sintering and melting processes was compared. The melting process was about 10 times more energy efficient than sintering in terms of material consolidation, demonstrating the promising potential of laser melting technologies of anorthosite-rich regolith for the production of structural elements. KW - Additive Manufacturing KW - Laser melting KW - ISRU KW - Moon KW - Regolith PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-639614 DO - https://doi.org/10.1016/j.amf.2025.200226 SN - 2950-4317 VL - 4 IS - 3 SP - 1 EP - 13 PB - Elsevier Ltd. AN - OPUS4-63961 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Geffroy, P.-M. A1 - Schubert, Nils Hendrik A1 - Günster, Jens A1 - Zocca, Andrea T1 - Quantification of in-plane stress development during drying of tape-cast ceramic layers by cantilever deflection method N2 - The control of stress development in cast ceramics during drying is usually one of critical steps in ceramic processes, which is important also for additive manufacturing technologies using a suspension as feedstock. This work introduces a method based on the cantilever deflection method, to simultaneously quantify the kinetics of solvent evaporation, the shrinkage and the intensity of in-plane stresses developed during drying. Particular attention is given here to the experimental limits of the method and to the optimization of the experimental conditions to suitably measure the intensity of in-planar stress in the coating. The optimized method is applied to four alumina slurries for the water-based additive manufacturing technology LSD-print. Four stages of drying are identified and discussed in relation with the granulometry and morphology of the alumina ceramic particles. KW - Additive Manufacturing KW - Tape casting KW - Ceramic layers KW - Drying stress PY - 2025 DO - https://doi.org/10.1016/j.jeurceramsoc.2024.116868 VL - 45 IS - 1 SP - 1 EP - 10 PB - Elsevier B.V. AN - OPUS4-61044 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Günster, Jens A1 - Wang, Gong A1 - Tian, Xiaoyong T1 - 3D Printing Technologies for Extreme Environment in Space N2 - 3D printing technology can realize the rapid fabrication of complicated structures with short production chain, which just meet the requirements for space manufacturing in the future. However, 3D printing technologies in space are still challenging due to the harsh conditions, such as microgravity, high vacuum, and large temperature difference. Meanwhile, in-situ resource utilization and recycling must be considered as a cost effective and resilient resource for 3D printing in space. On the contrary, extreme environmental conditions such as high vacuum and microgravity can also offer significant advantages for advanced materials with high purity and performance. In-situ fabrication of ultra-large components would overcome the weight and structural limitations imposed by rocket launch and change the future strategy for space exploration. The aim of this specially issue is therefore to provide a platform for discussing the potential technologies for 3D printing in space. KW - Additive Manufacturing KW - space PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-652654 DO - https://doi.org/10.1016/j.amf.2025.200248 SN - 2950-4317 VL - 4 IS - 3 SP - 1 EP - 2 PB - Elsevier AN - OPUS4-65265 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Fritsch, Tobias A1 - Ferrari, Bruno A1 - Altmann, Mika León A1 - Bruno, Giovanni A1 - Toenjes, Anastasiya T1 - Laser powder bed fusion: Defect type influences critical porosity re-growth during reheating after hot isostatic pressing N2 - Despite the remarkable product design flexibility offered by additive manufacturing (AM) techniques, such as laser powder bed fusion, AM processes are susceptible to the formation of defects. In this context, the control of process parameters and the application of post-processing treatments, such as hot isostatic pressing (HIP), are of paramount importance to achieve the desired mechanical properties. The present study investigates the effectiveness of HIP as a function of process parameters in laser powder bed fused Ti-6V-4Al (PBF-LB/Ti64) using X-ray computed tomography. The process parameters are modified to obtain reference samples with low porosity, lack of fusion defects, or keyhole porosity. In all instances, subsurface keyhole porosity was observed in the as-built parts. Moreover, it was found that the efficacy of pore closure is dependent on the specific defect type. In the case of low porosity and keyhole pores, HIP resulted in effective closure. Conversely, larger lack of fusion defects were not closed due to their interconnectivity and the entrapment of argon gas. Subsequent heat treatments above the β-transus temperature allowed the investigation of the impact of defect type on porosity re-growth. For the first time, we reveal that lack of fusion defects are affected by considerable pore re-growth during post-HIP heat treatments of PBF-LB/Ti64. Such phenomenon is driven by the increasing internal pore pressure and local creep deformation at high temperatures. In contrast, re-growth is limited in samples with low porosity or keyhole pores. KW - Additive Manufacturing KW - Hot Isostatic Pressing KW - Titanium KW - Laser Powder Bed Fusion KW - X-ray Computed Tomography KW - Heat Treatment KW - Porosity PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-629289 DO - https://doi.org/10.1016/j.jmatprotec.2025.118839 VL - 340 SP - 1 EP - 9 PB - Elsevier B.V. AN - OPUS4-62928 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -