Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Additive manufacturing of metal assemblies with formed sheet-body

Project Status: Active


Fundamental understanding of a new and innovative process combining sheet metal forming with additive manufacturing is the main goal of this research work. Within the first phase of the Collaborative Research Center 814 (CRC 814) it has been the aim to develop a process chain which allows manufacturing functional elements on deep drawn Ti‑6Al‑4V sheet-body parts. To gain fundamental knowledge about the effect of different stress states in the base plate on the additive manufacturing process the second phase of the Collaborative Research Center 814 will add bending of Ti‑6Al‑4V sheet metal to the processes combined with additive manufacturing. Laser beam melting will be utilized as additive manufacturing process and applied before and after the bending operation in order to achieve hybrid manufactured parts, combining sheet metal forming and additive manufacturing. Advantages of both manufacturing technologies, such as the high geometrical flexibility of additive manufacturing and large scaled geometries achievable by sheet metal forming, will be merged.

The scientific focus of the research project is to investigate the interaction between thermomechanical stress and deformation and the interaction between additive manufacturing and forming. First of all, the influence of each manufacturing step on the following one is studied. Second, physical and microstructural correlations will be detected and decoded. Based on this knowledge limits and possibilities for the combination of sheet metal forming and additive manufacturing can be pointed out.

Prozesskette Warmbiegen

Schematic process chain for the combination of sheet metal forming and additive manufacturing - from sheet metal to hybrid part


Research Groups



    • Papke, T.; Junker, D.; Huber, F.; Hentschel, O.; Schmidt, M.; Merklein, M.:
      Verknüpfung additiver Fertigung und Umformtechnik in Form hybrider Bauteile und Werkzeuge.
      In: (Edtr.): 2018, accepted


    • Dubjella, P.; Merklein, M.:
      Influence of Warm Bending on the Surface Topography of Titanium Alloy Ti-6Al-4V.
      Procedia Engineering 183(2017), pp. 23-30

    • Butzhammer, L.; Dubjella, P.; Huber, F.; Schaub, A.; Aumüller, M.; Baum, A.; Petrunenko, O.; Merklein, M.; Schmidt, M.:
      Experimental investigation of a process chain combining sheet metal bending and laser beam melting of Ti-6Al-4V.
      In: WLT e.V. (Edtr.): Lasers in Manufacturing Conference 2017, 2017, accepted


    • Schaub, A.; Degner, J.; Ahuja, B.; Schmidt, M.; Merklein, M.:
      Numerical Investigation for Superplastic Forming Tool Development Within the Combined Process Chain of Forming and Additive Manufacturing.
      In: Dimitrov, D; Oosthuizen, T. (Edtrs.): Int. Conf. Competitive Manufacturing, 2016, pp. 173-179

    • Merklein, M.; Junker, D.; Schaub, A.; Neubauer, F.:
      Hybrid Additive Manufacturing Technologies - An Analysis regarding Potentials and Applications.
      Procedia Engineering 83(2016), pp. 549 - 559

    • Schaub, A.; Bhrigu, A.; Butzhammer, L.; Osterziel, J.; Schmidt, M.; Merklein, M.:
      Additive manufacturing of functional elements on sheet metal.
      Physics Procedia 83(2016), pp. 797-807

    Letztes Update: 15.09.2017