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Multi-material approach to integrate ceramic boxed temperature-sensitive components in laser beam melted structures for bio and other applications

: Lausch, Holger; Töppel, Thomas; Petters, Romy; Gronde, Bernd; Herrmann, Mathias; Funke, Kerstin

3rd Fraunhofer Direct Digital Manufacturing Conference, DDMC 2016. Proceedings : 16-17 March 2016, Berlin, Germany
Stuttgart: Fraunhofer Verlag, 2016
ISBN: 978-3-8396-1001-5
8 pp.
Fraunhofer Direct Digital Manufacturing Conference (DDMC) <3, 2016, Berlin>
Conference Paper
Fraunhofer IWU ()
Fraunhofer IKTS ()
laser beam melting; sensor technology; actuating elements; embedding; functional integration; functional consolidation; additive manufacturing; plasma spraying; Multi-Material; multi-layer; thermal protection; ceramic; metal; actuators; sensors

The form-locked, force-fit and materially bonded integration of temperature-sensitive actuators and sensors in complex metal parts or metallic monolithic structures is still a dissolved problem. On the one hand, embedded actuators and sensors require an optimum shape and material connection to optimally low loss coupling the desired measuring gradient (gradient force) to the sensor and to low loss coupling the actuating gradient (gradient force) into the structure where the actuator/sensor is embedded in. On the other hand, the actuators/sensors need to be materially bonded at interfaces with its surrounding structure with thermal protection from laser melting process.
Such a strategy assumes that the actuator/sensor is coated by a thermal-shielding multi-material/multi-layer protection system preferably from ceramic and metallic material components. The integration interface between actuator/sensor system and surrounding structure is thereby designed in such a way that the main flow of energy is topically focused on this interface and distributed away from and around the actuator/sensor system. In this way, the total energy input into the temperature-sensitive actuator/sensor system is reduced. Also addressed are laser scanning patterns for less topical temperature load. In this article solutions for above described problems for a monolithic and function-preserving integration of actuator/sensor systems inside and outside laser beam melted components are discussed. These mechatronic systems can be used for various applications such as medical implants and industrial parts.